Quenched Granular Absorbent and System and Method for Making Quenched Granular Absorbent

ABSTRACT

A system and method of extruding self-clumping granular absorbent having cold water soluble amylopectin starch binder formed from starch-containing admixture sufficient for extruded sorbent pellets to produce flowable binder flowing between pellets clumping them together producing clumps of pellets that become hard when substantially dry that have a crush strength of at least 25 PSI and clump retention of at least 80% and preferably at least 90%. As a result, dried pellet clumps are easy to pick up leaving behind unspent pellets for continued sorbent use. A pellet quenching apparatus and method rapidly cools and dries pellets before leaving the extruder preventing loss of cold water soluble starch and binder, preventing pellet shrinkage, and preventing pellet densification. An air conveyor transporting quenched pellets removed from the extruder further cools and dries the pellets producing pellets ready for sorbent use.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/114,069, filed Jul. 25, 2016, which is US national stage ofPCT/US2015/012969, filed Jan. 26, 2015, which claims priority in USProvisional Patent Application Nos. 61/952,133, filed Mar. 12, 2014 and61/931,609, filed Jan. 25, 2014, the entirety of each of which arehereby expressly incorporated herein by reference.

FIELD

The present invention is directed to granular absorbent and moreparticularly to a clumping granular absorbent that adsorbs and absorbswater and water-insoluble liquids that is well suited for use as animallitter and oil absorbent, a system used to make granular absorbent, anda method of making such granular absorbent including quenching bycooling and drying upon and following extrusion.

BACKGROUND

While attempts have been made in the past to produce a lighter, morenatural, and even biodegradable cat litter, improvements nonethelessremain desirable. Conventional clay-based and gel-based litters arerelatively heavy, cost a considerable amount of money to ship, are notbiodegradable, and are often a burden for purchasers to carry. Whilemany so-called natural cat litters have been introduced into themarketplace, they can be nearly as heavy as conventional litter,typically absorb far less urine than conventional litter, can producetheir own unpleasant odor, and many times do not clump well, if theyeven clump at all.

Attempts have also been made in the past to make granular absorbents,including cat litter, from starch-containing admixtures, includingcereal grain admixture, but they are believed to date to have enjoyedlittle, if any, commercial success. Past attempts have produced extrudedgranular absorbents that absorb poorly, require grinding or shatteringof the granular absorbent before use, and are challenging to pick upafter use.

What is needed is a natural granular absorbent that overcomes one ormore of the aforementioned drawbacks.

SUMMARY

The present invention is directed to a granular absorbent extrusionsystem and method of making granular absorbent in accordance with thepresent invention producing sorbent granules or pellets that absorb andadsorb liquids, including water, urine, liquid fecal matter, oil andother water insoluble/immiscible liquids which can form clumps ofpellets when pellets are wetted with water that become substantiallyhard when dried enabling the clumps of spent or used granular absorbentto be easily picked up and disposed of after use. A preferred method ofmaking granular absorbent extrudes absorbent pellets from astarch-containing mixture using an extruder, e.g., extrusion cooker,having sufficient water-soluble binder in each pellet to form a flowableadhesive when the pellet is wetted that flows from the pellet onto andaround adjacent pellets adhering them together forming clumps.

The mixture or admixture containing sufficient starch that sorbentgranules extruded therefrom each contain water-soluble binder formed byphysically converting or modifying starches in the mixture in an amountsufficient to form clumps of pellets when wetted that have a clump crushstrength of at least 25 pounds per square inch and a clump retentionrate of at least 80% when substantially dry. One preferredstarch-containing mixture is formed of one or more cereal grains, whichcan be comminuted or ground, fiber, and other constituents or additives,containing sufficient starch for a enough water-soluble binder to beformed in each pellet by physically converting or modifying starches inthe mixture during extrusion to produce self-clumping sorbent pelletsthat provide their own clumping binder when wetted. Such a preferredstarch-containing mixture contains enough starch that cold water solublestarch binder, preferably cold water soluble amylopectin binder, andmore preferably an amorphous cold water soluble amylopectin binder, isformed in each pellet by starch molecular weight reducing starchconversion or modification during extrusion in an amount sufficient toflow binder from each wetted pellet to clump wetted pellets together.

In a preferred method of making self-clumping granular absorbent,pellets extruded from such a starch-containing mixture form at least 10%water soluble starches by uncoated pellet weight in each pelletincluding a sufficient amount of water soluble starch binder for thepellets to self-clump. In one preferred method and granular absorbent,starches in the mixture are physically modified or converted, e.g.causing starch molecular weight reduction, during extrusion intowater-soluble starches in an amount of at least 15% cold water-solublestarches, including sufficient cold water soluble starch binder, toproduce self-clumping sorbent pellets that form clumps each having aclump crush strength of at least 25 pounds per square inch and a clumpretention rate of at least 80% when substantially dry. In anotherpreferred method and granular absorbent, sorbent pellets are extrudedhaving at least 15% cold water soluble starch binder, preferably coldwater soluble amylopectin binder, in each pellet formed by convertingstarches in the mixture during extrusion producing self-clumping sorbentpellets that form clumps when wetted having a clump crush strength of atleast 25 pounds per square inch and a clump retention rate of at least90%, preferably at least 95%, when substantially dry. In carrying outpreferred methods of making granular absorbent in accordance with thepresent invention, sorbent pellets are extruded having a water-solublestarch binder contents, including cold water soluble amylopectin starchbinder contents, ranging between 15% to as much as 55%, producingself-clumping granular sorbent pellets of the present invention havingclump crush strengths ranging between 25 pounds per square inch and 65pounds per square inch with clump retention rates ranging between 80%and 99%.

While extruded granular materials, including in granule or pellet form,have typically been dried after extrusion on a conveyor in a heated ovenat temperatures well above ambient, typically above 250 degreesFahrenheit, a method and granular absorbent extrusion system inaccordance with the present invention quenches the sorbent pelletsimmediately upon extrusion and before being removed from the extruderproducing improved sorbent pellets of granular absorbent. Wherepost-extrusion quenching is performed, the granular absorbent extrusionsystem includes a pellet quenching apparatus that quenches each pelletimmediately upon extrusion, and preferably at least until the pelletleaves the extruder, rapidly cooling and preferably flash drying eachpellet.

In oven drying granules or pellets of extruded granular material, theextruded granules or pellets are typically delivered from the extruderonto the oven conveyor with minimal or no cooling or drying occurringbeforehand. It has been found that oven drying granular absorbent notonly takes time and consumes expensive energy, it actually reduces theabsorptivity of the granular absorbent. Where the extruded granularabsorbent contains water-soluble starches, including water-solublestarch binders, it has been learned that oven drying reduces the amountof water solubles, including water-soluble binder, present in eachsorbent pellet after oven drying. It has also been learned that sorbentpellets immediately upon extrusion are relatively hot and moist suchthat absorptivity and clumping ability is dramatically reduced evenduring the time the sorbent pellets are being transported to the dryingoven. Not only is the water-soluble starch, including water-solublestarch binder, content of each extruded pellet significantly reduced,but the moisture causes each pellet to shrink significantly. Wheremaintaining a desired pellet density is important, this post-extrusionmoisture induced shrinkage densities each pellet undesirably increasinggranular absorbent bulk density.

In a preferred quenching apparatus and quenching method, quenching gas,preferably air, is delivered to a quenching chamber surrounding adischarge end of the extruder directing quenching air onto sorbentpellets as they are being extruded out an extruder die and cut from thedie by a rotary cutter of the extruder. Quenching air at a sufficientvolumetric flow rate, low enough temperature below pellet extrusiontemperature, and low enough moisture content, e.g., humidity, isdelivered from an air mover to the quenching chamber producing turbulentflow within the quenching chamber that not only convectively cools thepellets thereby quenching them, but also carries the pellets in thequenching air gas flow to a pellet discharge where the quenched extrudedpellets are then removed from the extruder.

During quenching, the pellets are cooled at least 15 degrees Celsiusbelow the pellet extrusion temperature before the pellets leave thequenching chamber leaving the extruder. The turbulently flowingquenching air evaporatively dries each pellet rapidly removing,preferably by evaporation, moisture vaporized in each pellet duringextrusion preventing excessive buildup in moisture on an outer surfaceof each pellet as well as in an outermost portion of each pellet. Rapidremoval of vaporized moisture from each pellet advantageously preventspellet shrinkage preferably by preventing water-soluble starches in theouter pellet surface from dissolving or solubilizing and collapsing eachpellet shrinking the pellet. By preventing pellet shrinkage due towater-soluble starch solubilization, the amount of water solublestarches, including water-soluble starch binder, present in each pelletimmediately after extrusion is advantageously preserved therebymaximizing pellet absorption and pellet clumping.

In addition, rapid cooling of each pellet by quenching each pelletimmediately upon extrusion, and preferably during extrusion, producessorbent pellets with a greater water soluble starch content thatpreferably also have a greater amount of water-soluble starch binderpresent in each pellet. This is because cooling each pellet during andimmediately after extrusion by quenching advantageously preventsphysically modified or converted starches, including amorphous starches,such as cold water-soluble amylopectin, preferably amorphous cold watersoluble amylopectin binder, whose molecular weight was reduced duringpellet extrusion, from changing phase or structure including bypreventing amorphous starches formed during physical conversion ormodification during extrusion from losing their amorphous state, e.g.preventing crystallization or retrogradation. Preferably, quenchingfreezes or locks amorphous water-soluble starches, including amorphouswater soluble starch binders, preferably amorphous cold water-solubleamylopectin binder, crystallization or retrogradation of suchamylopectin starches preferably is prevented or at least reduced byquenching.

Such rapid cooling of each pellet by quenching can accelerateretrogradation of amylose starches in each pellet, including physicallyconverted or modified amylose starches whose molecular weight wasreduced during pellet extrusion. Where quenching rapidly retrogradesamylose starches in each pellet, retrogradation of amylose starchespreferably strengthens or stiffens each pellet including by forming astarch matrix, preferably including more formed of amylose, that isstiffer and better maintains liquid adsorbing voids and pores formed ineach pellet improving pellet adsorption and/or absorption.

As a result of pellet quenching, the outer surface pores, outer surfaceirregularities, outer surface depressions, cracks, and other threedimensionally contoured outer surface features of each extruded pelletformed during extrusion is better preserved, preferably substantiallypreserved, thereby producing quenched extruded pellets having increasedsurface roughness with at least a plurality of surface pores that morereadily adsorb and/or absorb liquids, including water, during sorbentuse. As a result of pellet quenching, internal absorptivity improvingvoids or pockets produced during expansion or puffing during extrusionare advantageously better preserved, more numerous and larger furtherincreasing pellet adsorption and absorption during granular sorbent use.

In a preferred quenching apparatus embodiment, a quenching air deliveryconduit has an outlet in gas flow communication with the quenchingchamber directing turbulently flowing quenching air across the diecarrying the extruded pellets in the quenching airflow to a dischargewhere the pellets are then removed from the extruder. In one preferredembodiment, a knife cage enclosing the die and cutter at the dischargeend of the extruder forms a plenum that is positively pressurized by thequenching air that is at least part of the quenching chamber. Thequenching chamber can and preferably also includes a pellet collectorbelow the knife cage with extruded pellets being quenched and carried bythe turbulent quenching airflow from the knife cage to the pelletcollector without contacting the knife cage. Both the knife cage and thepellet collector can be of substantially airtight construction tofacilitate quenching and pellet transport during quenching from theextruder die into the pellet collector and out the discharge.

A method of extruding granular absorbent with a granular absorbentsystem equipped with a pellet quenching apparatus of the presentinvention advantageously produces quenched extruded sorbent pelletshaving improved absorptivity and clumping. Quenched extruded pellets ofgranular sorbent of the present invention are self-clumping bydissolving and flowing water soluble binder from wetted pellets inbetween adjacent pellets hearing and clumping them together. Quenchedextruded pellets of granular sorbent of the present inventionadvantageously also form clumps that become substantially hard when dryhaving excellent crushed clump strength and excellent clump retention.

A granular absorbent system constructed in accordance with the presentinvention can also include a pneumatic conveyor with a pellettransporting conduit in gas flow communication with the discharge of thepellet collector or quenching chamber that further cools and dries thepellets as they are transported to a location remote from the extruder.

Cooling and drying advantageously is performed using quenching air drawnfrom air at ambient temperature such that cold quenching of the extrudedpellets are performed producing improved sorbent pellets of granularabsorbent of the present invention with increased absorptivity, clumpingability, and which are shelf stable at room temperatures for months, ifnot years, producing granular absorbent that is stable, natural, e.g.organic, biodegradable, and economical that is particularly well suitedfor animal litter, oil absorbent and other liquid absorbentapplications.

These and other objects, features and advantages of this invention willbecome apparent from the following detailed description of the inventionand accompanying drawings.

DRAWING DESCRIPTION

One or more preferred exemplary embodiments of the invention areillustrated in the accompanying drawings in which like referencenumerals represent like parts throughout and in which:

FIG. 1 illustrates a top perspective view of a granular absorbentextrusion system equipped with a pellet quenching apparatus of thepresent invention used in making extruded granular sorbent;

FIG. 2 is a fragmentary side elevation view an extruder or extrusioncooker illustrating an extrudate discharge chamber at a discharge end ofthe extruder formed of one or both of knife cage and pellet collectorthat forms part of the pellet quenching apparatus;

FIG. 3 is enlarged side elevation view of pellet quenching air plenum ofthe pellet quenching apparatus formed of a pellet quenching air flowdistributor and knife cage shown in phantom that preferably issubstantially air-tightly sealed forming a substantially gas-tightheadbox;

FIG. 4 is enlarged side elevation view of part of the extrudatedischarge chamber at the discharge end of the extruder with the knifecage removed for clarity depicting the pellet quenching air flowdistributor blowing pellets as they extruded into a pellet collectorbelow;

FIG. 5 is a fragmentary top perspective view of the discharge end of theextruder and part of the extrudate discharge chamber illustrating thequenching air plenum in phantom; and

FIG. 6 is an enlarged fragmentary view of the quenching air plenum shownin phantom depicting engagement of a rotary cutter with a perforateextruder die carried by a discharge end of a barrel of the extruder.

Before explaining one or more embodiments of the invention in detail, itis to be understood that the invention is not limited in its applicationto the details of construction and the arrangement of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments, which can be practiced orcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-6 illustrate a preferred embodiment of a granular absorbentextrusion system 40 for extruding a starch-containing admixture formingextruded granules or pellets 42 of granular sorbent 44 that are not onlywater sorbent and particularly well suited for use as animal litter butwhich in at least one embodiment preferably also is oil sorbent andthereby also suitable for use as oil absorbent. The granular sorbent 44is formed from starch-containing admixture having sufficient starch sothat when starch in the admixture is gelatinized, melted, and/ordegraded and extruded by an extruder 46 at a desirably high enoughextruder pressure and extruder temperature, sorbent pellets 42 areformed each having enough starch-based liquid soluble binder thatsufficiently wetted pellets 42 adhere or clump to one another during useproducing self-clumping granular sorbent 44. In at least one preferredmethod and embodiment, the extruded granular sorbent 42 is organicgranular sorbent 42 and the pellets 42 of such extruded organic granularsorbent 42 are biodegradable. A preferred starch-containing admixtureincludes one or more cereal grains and can be formed substantiallycompletely of the one or more cereal grains extruding sorbent pellets 42of the invention that are organic, biodegradable, and which can also betoilet flushable under certain circumstances.

The granular absorbent extrusion system 40 has an extruder 46 thatpreferably is a single screw extruder but which can also be a twin screwextruder if desired. A preferred method of making granular absorbent 44in accordance with the present invention utilizes a starch-containingadmixture having sufficient starch and a low enough moisture contentextruded from the extruder 46 at a high enough extruder temperature andpressure to form extruded absorbent pellets 42 each having at least 10%water-soluble starches by uncoated pellet weight including sufficientstarch-based water-soluble binder, preferably cold water soluble starchbinder, for pellets 42 to adhere to one another when wetted includingforming clumps of pellets 42 that become substantially hard when dry.

The granular absorbent extrusion system 40 can also be equipped with apellet quenching apparatus 48 that quenches each pellet 42 immediatelyupon extrusion rapidly cooling and preferably also drying at least aportion of an outer surface of each pellet 42 before being transportedfrom the extruder 46 to a location remote from the extruder 46. Wherethe granular absorbent extrusion system 40 is equipped with a pelletquenching apparatus 48, quenching of the extruded pellets 42 before thepellets 42 are removed from the extruder 46 reduces the temperature ofthe pellets 42 by at least about 25 degrees Celsius or by at least about45 degrees Fahrenheit to a temperature no greater than about 83 degreesCelsius or no greater than 180 degrees Fahrenheit. Quenching preferablyalso dries each pellet 42 by rapidly removing vaporized moistureescaping from the pellet 42 that would ordinarily dissolve or solubilizewater soluble starches, including cold water soluble starches,preventing pellet shrinkage while optimizing water absorption andclumping.

Where a pneumatic conveyor 99 is used to remove the quenched extrudedpellets 42 from the extruder 46 and transport the pellets 42 to theremote location, further pellet cooling and drying is performed duringpneumatic conveyor transport cools the pellets 42 to a temperature nohigher than about 45 degrees Celsius or no higher than about 113 degreesFahrenheit. Where a pneumatic conveyor 99 is used to remove the quenchedextruded pellets 42 from the extruder 46 and transport the pellets 42 tothe remote location, further pellet cooling and drying is performedduring pneumatic conveyor transport that cools the pellets 42 to atemperature no higher than about 43 degrees Celsius or no higher thanabout 110 degrees Fahrenheit and preferably also dries the pellets 42 toa moisture content no greater than about 13% by uncoated pellet weight.

Cooling and drying of granular sorbent 44 of the present invention isadvantageously done during quenching and pneumatic conveyor transportwithout having to heat the pellets 42 after extrusion to dry them, whichnot only saves time and energy but also helps prevent loss of clumpingwater soluble starches resulting in pellets 42 that form substantiallyhard clumps during sorbent use that retain material in liquid absorbedand adsorbed in the clump after the clump dries.

Granular Sorbent and Method of Extruding Granular Sorbent

The extruder 46 has an elongate generally cylindrical barrel 58 carryinga circular or disk-shaped perforate extrusion die 60 from which at leasta plurality of pairs, i.e., at least three, of pellets 42 are extrudedper second during extruder operation. The pellets 42 are formed from“ropes” or strings of extrudate (not shown) exiting substantiallysimultaneously from a plurality of pairs of bores or openings 61 (FIG.6) in the die 60 which are cut into pellets 42 by a rotary cutter 62 ona cutting shaft 64 rotated by an electric motor 66 during extruderoperation. During extrusion, the “ropes” or strings of extrudate aresqueezed out or flow from the die openings 61 in an axial directiongenerally parallel to an axis of rotation of the cutter shaft 64 towardthe rotary cutter 62, which slices them into pellets 42.

The knife cage 56 is a protective housing that encloses a discharge end68 of the extruder barrel, the die 60, cutter 62, and part of the cuttershaft 64. The knife cage 56 can be generally rectangular, e.g., square,having a top wall 73 and a plurality of pairs of sidewalls 75, 77, 79and 81. The knife cage 56 overlies a bottom opening 70 through whichpellets 42 in the knife cage 56 pass into a pellet-collecting hopper 71,e.g. pellet collector 72, which can form or be part of the extrudatedischarge chamber 47. The knife cage 56 has a necked down funnel 83 atits bottom that helps direct or funnel pellets 42 into the opening 70 ofthe pellet collector 72. Pellets 42 received in the pellet collector 72after passing through the knife cage 56 are conveyed therefrom via apellet discharge 74 in fluid-flow communication with a bottom portion ofthe pellet collector 72.

The pellet collector 72, e.g., hopper 71, can also be generallyrectangular, e.g., square. As best shown in FIGS. 1 and 2, the collector72 is formed of a top 76, plurality of pairs of sidewalls 78, 80, 82,84, and a bottom 86 forming a pellet collecting hopper 71, e.g., pelletcollector 72, which can be gravity fed by the knife cage 56 duringextruder operation. While the pellet collector 72 can be and preferablyis of generally gas-tight, i.e., airtight, construction, one or more oftop, walls and bottom, 76, 78, 80, 82 and/or 84 can include one or moreports (not shown) through which ambient atmosphere outside the collector72 and extruder 46 can enter during operation. One of the walls 78 ofthe pellet collector 72 can include an access door 88 which can beequipped with a sight glass 90 in the form of a transparent panel madeof plastic, e.g. clear acrylic, glass, e.g., tempered glass, or anothersuitable see-through material. The sight glass 90 enables viewing insidethe pellet collector 72 during operation and the access door 88 providesaccess inside the collector 72 when needed to clean, service orotherwise inspect inside the collector 72.

As is best shown in FIG. 1, the pellet discharge 74 includes at leastone duct and preferably a plurality of elongate hopper pellet dischargeducts 92, 94 that each can independently and preferably bothsubstantially simultaneously convey pellets 42 received in the pelletcollector 72 away from the extruder 46. The ducts 92, 94 can begenerally horizontal, spaced apart, and generally parallel to oneanother arranged in a side-by-side arrangement with each duct 92, 94 influid-flow communication with opposite sides of the collector 72adjacent the hopper bottom 86 to better prevent pellet accumulationduring extruder operation.

The ducts 92, 94 can converge using a wye 96 into an elongate commonpellet discharge conduit 98, only a portion of which is shown in FIG. 1,used to transport pellets 42 from the pellet collector 72 to a locationremote from the extruder 46 where the pellets 42 can be processed suchas by cleaning, abrading, classifying, drying, treating and/or packagingthe pellets 42. In a preferred embodiment, the ductwork of the discharge74 is part of a pneumatic conveyor 99 to which a plurality of extruders46 are connected to substantially simultaneously transport pellets 42 asthey are extruded from a plurality of extruders 46 operating at the sametime in the same plant or production facility.

During pneumatic conveyor operation, one or more blowers, fans, or otherair moves are operated to move air through the ductwork of the pneumaticconveyor 99 transporting pellets 42 from the pellet collector 72 of eachextruder 46 to at least one remote location. Air flowing through theductwork preferably sucks pellets 42 from at or adjacent the bottom ofthe collector 72 into one or both ducts 92, 94, including substantiallysimultaneously, transporting the pellets 42 conduit 98 to the at leastone remote location. Doing so preferably creates a pressure differentialwithin the pellet collector 72, e.g. a vacuum, which facilitates suckingpellets 42 in the collector 72 into ducts 92, 94.

In a preferred method of making granular sorbent in accordance with thepresent invention by extrusion using extruder 46, a starch-containingadmixture is formed of one or more cereal grains, such as corn and/orsorghum, producing a starch-containing admixture having at least 40%starch and preferably at least 50% starch by dry admixture weight andwhich possesses a moisture content no greater than 25% by dry admixtureweight. One or more other cereal grains, including maize, wheat, rice,triticale, barley, millet, rye, quinoa and buckwheat, as well ascombinations thereof, can be used. The admixture can include fiber,preferably insoluble fiber, e.g., cellulose or cellulosic fiber, in anamount preferably not more than 40% by dry admixture weight. Where theadmixture includes fiber, a preferred fiber containing admixturecontains between 5% and 30% fiber by dry admixture weight. In onepreferred fiber-containing admixture, the admixture contains between 10%and 25% fiber and can contain between 5% and 15% fiber. Where theadmixture contains fiber, preferred sources of fiber include alfalfa,oat fiber, wheat fiber, beet fiber, paper fiber, e.g., recycled paper,wood fiber, e.g., pine fiber, and other types or sources of cellulosecontaining or cellulosic fiber.

One preferred admixture is formed of substantially completely ofcomminuted or ground corn, e.g. cornmeal, corn grits, or corn starch,and the corn admixture can contain as much as 40% fiber by dry admixtureweight. Corn used in the admixture can be de-germed if desired. Wherethe corn admixture contains fiber, the admixture preferably containsbetween 5% and 30% fiber and can contain between 10% and 25% fiber. Thebalance of the admixture can contain other additives including colorant,dye, fragrances, scents, anti-bacterial additives, anti-fungaladditives, anti-yeast additives, urea or urease inhibitors, and/or otheradditives in an amount no greater than 10% and preferably in an amountno greater than about 5% of the admixture by dry admixture weight. Sucha preferred corn admixture preferably contains no more than 25% moisturecontent by admixture weight. One preferred corn admixture contains nobinders, adhesives, plasticizers, surfactants or emulsifiers and nobinders, adhesives, plasticizer, surfactants or emulsifiers used oradded during pellet extrusion.

Another preferred admixture is formed of substantially completely ofsorghum and the admixture can contain as much as 40% fiber by dryadmixture weight. The sorghum used preferably is whole grain sorghumthat has not been de-corticated or de-germed. Where the sorghumadmixture contains fiber, the admixture preferably contains between 5%and 30% fiber and can contain between 10% and 25% fiber. The balance ofthe admixture can contain other additives including colorant, dye,fragrances, scents, anti-bacterial additives, anti-fungal additives,anti-yeast additives, urea or urease inhibitors, and/or other additivesin an amount no greater than 10% and preferably in an amount no greaterthan 5% of the admixture by dry admixture weight. Such a preferredsorghum admixture preferably contains no more than 20% moisture contentby admixture weight. One preferred sorghum admixture contains nobinders, adhesives, plasticizers, surfactants or emulsifiers and nobinders, adhesives, plasticizer, surfactants or emulsifiers used oradded during pellet extrusion.

In a method of making self-clumping granular sorbent of the presentinvention, starch-containing admixture, preferably cereal grainadmixture, and more preferably corn and/or sorghum admixture, isextruded by an extruder 46, preferably a single screw extruder, of agranular absorbent extrusion system 40 of the present invention at anextruder temperature of at least 100 degrees Celsius and at an extruderpressure of at least 800 pounds per square inch (PSI) producing extrudedsorbent pellets 42 having at least 10% cold water-soluble starches byuncoated pellet weight, including sufficient cold water-soluble binderformed in each pellet 42 from starch in the admixture during extrusionfor the cold water-soluble binder to form a flowable adhesive that flowsfrom pellets 42 when wetted with water enabling clumping of wettedpellets 42 during sorbent use. In a preferred method, corn or sorghumadmixture is extruded at these extruder pressure and temperatureparameters in a single screw extruding without adding any water or steamduring extrusion forming sorbent pellets 42 each having at least 10%cold water soluble starch binder formed of starch in the admixtureduring extrusion extruding pellets 42 each having an amount of coldwater soluble starch binder, including at least some cold water solublebinder in an outer surface of each pellet 42, sufficient for at leastsome water soluble binder in each wetted pellet 42 to dissolve orsolubilize and flow between adjacent pellets 42 clumping, i.e.,“self-clumping,” at least a plurality of pairs, i.e., at least three, ofthe pellets 42 during sorbent use forming a clump of the pellets 42.

In one preferred method of extruding self-clumping granular sorbent ofthe present invention, the admixture is extruded by the extruder 46 atan extruder temperature of at least 120 degrees Celsius, preferably atleast 140 degrees Celsius, and at an extruder pressure of at least 900PSI, preferably at least 1000 PSI, extruding sorbent pellets 42 eachhaving at least 15% cold water-soluble starches in each pellet 42 byuncoated pellet weight formed from starch in the admixture preferablyconverted or melted during extrusion into cold water soluble starchesduring extrusion that includes at least 10% cold water soluble starchbinder in each pellet 42 sufficient for pellets 42 wetted with water toclump, e.g. “self-clump” producing self-clumping granular sorbent 44 ofthe present invention. In a preferred method, corn or sorghum admixtureis extruded without adding any water or steam during extrusion formingsorbent pellets 42 each having at least 15% cold water soluble starchbinder formed of starch in the admixture during extrusion containing anamount of cold water soluble starch binder in an outer surface of eachpellet 42 wetted with water to dissolve or solubilize and flow betweenadjacent pellets 42 clumping at least a plurality of pairs, i.e., atleast three, of pellets 42 together forming a clump of the pellets 42.

In another preferred method of extruding self-clumping granular sorbentof the present invention, the admixture is extruded by the extruder 46at an extruder temperature of at least 120 degrees Celsius, preferablyat least 140 degrees Celsius, and at an extruder pressure of at least900 PSI, preferably at least 1000 PSI, extruding sorbent pellets 42 eachhaving at least 20% cold water-soluble starches in each pellet 42 byuncoated pellet weight formed from starch in the admixture preferablyconverted or melted during extrusion into cold water soluble starchesduring extrusion that includes at least 15% cold water soluble starchbinder in each pellet 42 sufficient for pellets 42 wetted with water toclump, e.g. “self-clump” producing self-clumping granular sorbent 44 ofthe present invention. In a preferred method, corn or sorghum admixtureis extruded without adding any water or steam during extrusion formingsorbent pellets 42 each having at least 20% cold water soluble starchbinder formed of starch in the admixture during extrusion containing anamount of cold water soluble starch binder in an outer surface of eachpellet 42 wetted with water to dissolve or solubilize and flow betweenadjacent pellets 42 clumping at least a plurality of pairs, i.e., atleast three, of pellets 42 together forming a clump of the pellets 42.

In a further preferred method of extruding self-clumping granularsorbent of the present invention, the admixture is extruded by theextruder 46 at an extruder temperature of at least 120 degrees Celsius,preferably at least 140 degrees Celsius, and at an extruder pressure ofat least 900 PSI, preferably at least 1000 PSI, extruding sorbentpellets 42 each having at least 25% cold water-soluble starches in eachpellet 42 by uncoated pellet weight formed from starch in the admixturepreferably converted or melted during extrusion into cold water solublestarches during extrusion that includes at least 15% cold water solublestarch binder in each pellet 42 sufficient for pellets 42 wetted withwater to clump, e.g. “self-clump” producing self-clumping granularsorbent 44 of the present invention. In a preferred method, corn orsorghum admixture is extruded without adding any water or steam duringextrusion forming sorbent pellets 42 each having at least 25% cold watersoluble starch binder formed of starch in the admixture during extrusioncontaining an amount of cold water soluble starch binder in an outersurface of each pellet 42 wetted with water to dissolve or solubilizeand flow between adjacent pellets 42 clumping at least a plurality ofpairs, i.e., at least three, of pellets 42 together forming a clump ofthe pellets 42.

In still another preferred method of extruding self-clumping granularsorbent of the present invention, the admixture is extruded by theextruder 46 at an extruder temperature of at least 120 degrees Celsius,preferably at least 140 degrees Celsius, and at an extruder pressure ofat least 900 PSI, preferably at least 1000 PSI, extruding sorbentpellets 42 each having at least 30% cold water-soluble starches in eachpellet 42 by uncoated pellet weight formed from starch in the admixturepreferably converted or melted during extrusion into cold water solublestarches during extrusion that includes at least 25% cold water solublestarch binder in each pellet 42 sufficient for pellets 42 wetted withwater to clump, e.g. “self-clump” producing self-clumping granularsorbent 44 of the present invention. In a preferred method, corn orsorghum admixture is extruded without adding any water or steam duringextrusion forming sorbent pellets 42 each having at least 30% cold watersoluble starch binder formed of starch in the admixture during extrusioncontaining an amount of cold water soluble starch binder in an outersurface of each pellet 42 wetted with water to dissolve or solubilizeand flow between adjacent pellets 42 clumping at least a plurality ofpairs, i.e., at least three, of pellets 42 together forming a clump ofthe pellets 42.

In a further preferred method of extruding self-clumping granularsorbent of the present invention, the admixture is extruded by theextruder 46 at an extruder temperature of at least 120 degrees Celsius,preferably at least 140 degrees Celsius, and at an extruder pressure ofat least 900 PSI, preferably at least 1000 PSI, extruding sorbentpellets 42 each having at least 35% cold water-soluble starches in eachpellet 42 by uncoated pellet weight formed from starch in the admixturepreferably converted or melted during extrusion into cold water solublestarches during extrusion that includes at least 30% cold water solublestarch binder in each pellet 42 sufficient for pellets 42 wetted withwater to clump, e.g. “self-clump” producing self-clumping granularsorbent 44 of the present invention. In a preferred method, corn orsorghum admixture is extruded without adding any water or steam duringextrusion forming sorbent pellets 42 each having at least 35% cold watersoluble starch binder formed of starch in the admixture during extrusioncontaining an amount of cold water soluble starch binder in an outersurface of each pellet 42 wetted with water to dissolve or solubilizeand flow between adjacent pellets 42 clumping at least a plurality ofpairs, i.e., at least three, of pellets 42 together forming a clump ofthe pellets 42.

In yet another preferred method of extruding self-clumping granularsorbent of the present invention, the admixture is extruded by theextruder 46 at an extruder temperature of at least 120 degrees Celsius,preferably at least 140 degrees Celsius, and at an extruder pressure ofat least 900 PSI, preferably at least 1000 PSI, extruding sorbentpellets 42 each having at least 40% cold water-soluble starches in eachpellet 42 by uncoated pellet weight formed from starch in the admixturepreferably converted or melted during extrusion into cold water solublestarches during extrusion that includes at least 35% cold water solublestarch binder in each pellet 42 sufficient for pellets 42 wetted withwater to clump, e.g. “self-clump” producing self-clumping granularsorbent 44 of the present invention. In a preferred method, corn orsorghum admixture is extruded without adding any water or steam duringextrusion forming sorbent pellets 42 each having at least 40% cold watersoluble starch binder formed of starch in the admixture during extrusioncontaining an amount of cold water soluble starch binder in an outersurface of each pellet 42 wetted with water to dissolve or solubilizeand flow between adjacent pellets 42 clumping at least a plurality ofpairs, i.e., at least three, of pellets 42 together forming a clump ofthe pellets 42. The pellets 42 can be round, generally cylindrical,concave, convex, disk-shaped, flat, be irregularly shaped or haveanother shape.

Extruded porous and/or void-filled expanded or puffed sorbent pellets 42are preferably formed having sizes, i.e. lengths and/orwidths/diameters, ranging between 0.3 millimeter and 3.2 millimeters,preferably between 0.4 millimeter and 3 millimeters, a moisture contentof no greater than 15%, preferably less than 13%, by uncoated pelletweight, an uncoated pellet bulk density ranging between 5 pounds percubic foot and 50 pounds per cubic foot, preferably between 7 pounds percubic foot and 40 pounds per cubic foot, and a water absorptivity ofbeing able to absorb at least three times, preferably at least fivetimes, uncoated pellet weight in water. Where the pellets 42 are to beused as granular sorbent in uncoated form, the porous and/or void-filledpellets 42 are formed having sizes, i.e. lengths and/orwidths/diameters, ranging between 0.5 millimeter and 3 millimeters,preferably between 0.6 millimeter and 2.8 millimeters, a moisturecontent of no greater than 14%, preferably no greater than 12%, byuncoated pellet weight, an uncoated pellet bulk density ranging between18 pounds per cubic foot and 45 pounds per cubic foot, preferablybetween 20 pounds per cubic foot and 35 pounds per cubic foot, and awater absorptivity of being able to absorb at least three times,preferably at least five times, uncoated pellet weight in water.

Where the pellets 42 are to be coated, such as with a smectite,preferably bentonite, e.g., powdered bentonite, the pellets 42 areformed having sizes, i.e. lengths and/or widths/diameters, rangingbetween 0.3 millimeter and 3.2 millimeters, preferably between 0.4millimeter and 3 millimeters, a moisture content of no greater than 14%,preferably no greater than 12%, by uncoated pellet weight, an uncoatedpellet bulk density ranging between 4 pounds per cubic foot and 18pounds per cubic foot, preferably between 6 pounds per cubic foot and 12pounds per cubic foot, and a water absorptivity of being able to absorbat least three times, preferably at least five times, uncoated pelletweight in water. After coating, the coated sorbent pellets preferablyhave sizes, i.e. lengths and/or widths/diameters, ranging between 0.5millimeter and 5 millimeters, preferably between 0.5 millimeter and 4millimeters, a moisture content of no greater than 14%, preferably nogreater than 12%, by coated pellet weight, an coated pellet bulk densityranging between 18 pounds per cubic foot and 50 pounds per cubic foot,preferably between 20 pounds per cubic foot and 40 pounds per cubicfoot, and a water absorptivity of being able to absorb at least fourtimes, preferably at least five and a half times, coated pellet weightin water.

Each clump formed from such cold water-soluble starch and/or coldwater-soluble starch binder containing extruded sorbent pellets 42 ofthe present invention during sorbent use has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80%, preferably at least 90%, and morepreferably at least 95%, when the clump is dried to a moisture contentof no greater than 15% and preferably between 6%-12% by dry or driedclump weight when substantially dry. Clump retention or clump rate isdetermined using standard clay-based cat or animal litter clumpretention or clump retention rate test standards, test methods ortesting as known in the cat or animal litter art. Clump crush strengthpreferably is tested by placing a corresponding weight, e.g., 25 pounds,30 pounds, 40 pounds, 50 pounds and/or 65 pounds, on a one inch by inchsquare or block of the clump after the clump has hardened to a moisturecontent no greater than 15% that preferably is between 6% and 12% byclump weight and determining the weight above which the clump crushes,crumbles or otherwise falls apart.

In one such preferred granular sorbent embodiment, each clump formed ofsuch cold water-soluble starch-containing and/or cold water-solublestarch binder-containing extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 30 PSI and a clumpretention or clump retention rate of at least 80%, preferably at least90%, and more preferably at least 95%, when the clump is or becomessubstantially dry. In another preferred granular sorbent embodiment,each clump formed of such cold water-soluble starch-containing and/orcold water-soluble starch binder-containing extruded sorbent pellets 42of the present invention has a clump crush strength of at least 40 PSIand a clump retention or clump retention rate of at least 90%,preferably at least 95%, and more preferably at least 97%, when theclump is substantially dry. In still another preferred embodiment, eachclump formed of such cold water-soluble starch-containing and/or coldwater-soluble starch binder-containing extruded sorbent pellets 42 ofthe present invention has a clump crush strength of at least 50 PSI anda clump retention or clump retention rate of at least 95%, preferably atleast 97%, and more preferably at least 99%, when the clump issubstantially dry. In a further preferred embodiment, each clump formedof such cold water-soluble starch and/or cold water-soluble starchbinder containing extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 65 PSI and a clump retention orclump retention rate of at least 95%, preferably at least 97%, and morepreferably at least 99%, when the clump is substantially dry.

Pellet Quenching Method and Pellet Quenching Apparatus

Where an extruder 46 of a granular absorbent extrusion system 40constructed in accordance with the present invention is equipped with apellet quenching apparatus 48, the pellet quenching apparatus 48 isdisposed at a pellet discharge end 50 of the extruder 46 and quencheseach pellet 42 extruded by the extruder 46. The pellet quenchingapparatus 48 uses a fluid, preferably a gas, more preferably air, toquench each extruded pellet 42 during extruder operation. In a preferredpellet quenching apparatus 48, the quenching gas is air but can beanother suitable gas, such as nitrogen, helium, argon, or gas mixture.

A preferred embodiment of a granular absorbent extrusion system 40constructed in accordance with the present invention is depicted inFIGS. 1-6 and includes a pellet quenching apparatus 48 is constructedand arranged to quench each extruded pellet 42 by rapidly cooling eachpellet 42 upon extrusion enough to consolidate and/or set the phase orstate of one or more converted or modified starches formed in eachpellet 42 during extrusion preferably before each quenched extrudedpellet 42 is transported from the extruder 46 for subsequent cooling,drying, coating, classification, mixing, storage and/or packaging. In apreferred pellet quenching apparatus 48 and pellet quenching method inaccordance with the present invention, the pellets 42 are quenched uponextrusion using a sufficient volumetric flow rate of gas at low enoughtemperature and moisture content, e.g. humidity, to rapidly cool theextruded pellets 42 from an initial pellet extrusion temperature of thepellets 42 immediately upon pellet extrusion to a quenched pellettemperature that is at least 15 degrees Celsius or at least 30 degreesFahrenheit less than the pellet extrusion temperature when the pellets42 are removed from the extruder 46, preferably when being drawn out thepellet discharge 74. Quenching of the pellets 42 preferably also flashdries the pellets 42 such that the pellets 42 have a moisture content nogreater than 18%, preferably no greater than 15%, by uncoated pelletweight, when the quenched extruded pellets 42 exit the extruder 46 viathe pellet discharge 74. In a preferred quenching apparatus and method,extruded pellets 42 quenched substantially immediately upon extrusionare cooled to a temperature no greater than 83 degrees Celsius or 180degrees Fahrenheit and dried to a moisture content no greater than 18%,preferably no greater than 15%, by uncoated pellet weight by the timethe quenched extruded pellets 42 leave the extruder 46 and enter thepneumatic conveyor 99 via the pellet discharge 74.

In another preferred pellet quenching apparatus embodiment and pelletquenching method, quenching cools the pellets 42 extruded by theextruder 46 at least about 20 degrees Celsius or at least about 35degrees Fahrenheit below the initial pellet extrusion temperature by thetime the quenched extruded pellets 42 are removed from the extruder 46by being suctioned out the pellet discharge 74. Quenching of the pellets42 preferably also flash dries the pellets 42 such that the pellets 42have a moisture content no greater than 15%, preferably no greater than13%, by uncoated pellet weight, when the quenched extruded pellets 42exit the extruder 46 via the pellet discharge 74. In a preferredquenching apparatus and method, extruded pellets 42 quenchedsubstantially immediately upon extrusion are cooled to a temperature nogreater than about 80 degrees Celsius or no greater than about 175degrees Fahrenheit and dried to a moisture content no greater than 15%by uncoated pellet weight by the time the quenched extruded pellets 42leave the extruder 46 and enter the pneumatic conveyor 99 via the pelletdischarge 74.

In one preferred pellet quenching apparatus embodiment and method, airis used to quench each pellet 42 immediately upon extrusion to cooland/or dry each extruded pellet 42 before transport from the extruder 46in a manner that consolidates each pellet 42 by stabilizing pelletstructure, facilitating cold water-soluble starch formation, preventingloss of cold water-soluble starches, preserving pellet surfaceintegrity, and/or preventing post-extrusion pellet shrinkage. Apreferred pellet quenching apparatus 48 and pellet quenching method coldquenches each extruded pellet 42 with air having a temperature less thandrying oven temperature, preferably less than 100 degrees Celsius (212degrees Fahrenheit), more preferably less than 85 degrees Celsius (about185 degrees Fahrenheit), helping to stabilize the structure of convertedor modified amylose and amylopectin starches in each pellet 42 in amanner that increases pellet strength while also advantageouslyincreases the amount of cold water-soluble starches, including theamount of cold water-soluble binder, available in each pellet 42 duringsorbent use. One preferred pellet quenching apparatus 48 and pelletquenching method cold quenches each extruded pellet 42 with air at roomtemperature having a temperature preferably between 18 degrees Celsius(about 64 degrees Fahrenheit) and 26 degrees Celsius (about 79 degreesFahrenheit). In one preferred pellet quenching apparatus 48 and pelletquenching method, air at a temperature no greater than 28 degreesCelsius (about 82 degrees Fahrenheit) is drawn into the pellet quenchingapparatus 48 and used to cold quench each extruded pellet 42.

With continued reference to FIGS. 1-6, the pellet quenching apparatus 48includes a quenching gas supply 52 and a quenching gas deliveryarrangement 54 that transports quenching gas from the supply 52 to thedischarge end 50 of the extruder 46. In a preferred embodiment, the gasdelivery arrangement 54 is in fluid flow communication with a pelletquenching chamber 45 formed at least in part by a knife cage 56 thatencloses the discharge end 50 of the extruder 46 that is at least partof an extrudate discharge chamber 47 into which pellets 42 aredischarged as they are extruded. During operation of the quenchingapparatus 48, quenching gas from the supply 52 is conveyed by thedelivery arrangement 54 into the pellet quenching chamber 45 byintroducing quenching gas into the knife cage 56 (shown in phantom)during extruder operation to quench the extruded pellets 42 before thepellets 42 are transported from the extruder 46. Since the pelletquenching apparatus 48 is intended for use with extruder 46, theextruder 46 is first described below before returning to describe thequenching apparatus 48 in more detail.

The extruder 46 has an elongate generally cylindrical barrel 58 carryinga circular or disk-shaped perforate extrusion die 60 from which at leasta plurality of pairs, i.e., at least three, of pellets 42 are extrudedper second during extruder operation. The pellets 42 are formed from“ropes” or strings of extrudate (not shown) exiting substantiallysimultaneously from a plurality of pairs of bores or openings 61 (FIG.6) in the die 60 which are cut into pellets 42 by a rotary cutter 62 ona cutting shaft 64 rotated by an electric motor 66 during extruderoperation. During extrusion, the “ropes” or strings of extrudate aresqueezed out or flow from the die openings 61 in an axial directiongenerally parallel to an axis of rotation of the cutter shaft 64 towardthe rotary cutter 62, which slices them into pellets 42.

The knife cage 56 is a protective housing that encloses a discharge end68 of the extruder barrel, the die 60, cutter 62, and part of the cuttershaft 64. The knife cage 56 can be generally rectangular, e.g., square,having a top wall 73 and a plurality of pairs of sidewalls 75, 77, 79and 81. The knife cage 56 overlies a bottom opening 70 through whichpellets 42 in the knife cage 56 pass into a pellet-collecting hopper 71,e.g. pellet collector 72, which can form or be part of the extrudatedischarge chamber 47. The knife cage 56 has a necked down funnel 83 atits bottom that helps direct or funnel pellets 42 into the opening 70 ofthe pellet collector 72. Pellets 42 received in the pellet collector 72after passing through the knife cage 56 are conveyed therefrom via apellet discharge 74 in fluid-flow communication with a bottom portion ofthe collector 72.

The pellet collector 72, e.g., hopper 71, can also be generallyrectangular, e.g., square. As best shown in FIGS. 1 and 2, the collector72 is formed of a top 76, plurality of pairs of sidewalls 78, 80, 82,84, and a bottom 86 forming a pellet collecting hopper 71, e.g., pelletcollector 72, which can be gravity fed by the knife cage 56 duringextruder operation. While the pellet collector 72 can be and preferablyis of generally gas-tight, i.e., airtight, construction, one or more oftop, walls and bottom, 76, 78, 80, 82 and/or 84 can include one or moreports (not shown) through which ambient atmosphere outside the collector72 and extruder 46 can enter during operation. One of the walls 78 ofthe pellet collector 72 can include an access door 88 which can beequipped with a sight glass 90 in the form of a transparent panel madeof plastic, e.g. clear acrylic, glass, e.g., tempered glass, or anothersuitable see-through material. The sight glass 90 enables viewing insidethe pellet collector 72 during operation and the access door 88 providesaccess inside the collector 72 when needed to clean, service orotherwise inspect inside the collector 72.

As is best shown in FIG. 1, the pellet discharge 74 includes at leastone duct and preferably a plurality of elongate hopper pellet dischargeducts 92, 94 that each can independently and preferably bothsubstantially simultaneously convey pellets 42 received in the pelletcollector 72 away from the extruder 46. The ducts 92, 94 can begenerally horizontal, spaced apart, and generally parallel to oneanother arranged in a side-by-side arrangement with each duct 92, 94 influid-flow communication with opposite sides of the collector 72adjacent the hopper bottom 86 to better prevent pellet accumulationduring extruder operation.

The ducts 92, 94 can converge using a wye 96 into an elongate commonpellet discharge conduit 98, only a portion of which is shown in FIG. 1,used to transport pellets 42 from the pellet collector 72 to a locationremote from the extruder 46 where the pellets 42 can be processed suchas by cleaning, abrading, classifying, drying, treating and/or packagingthe pellets 42. In a preferred embodiment, the ductwork of the discharge74 is part of a pneumatic conveyor 99 to which a plurality of extruders46 are connected to substantially simultaneously transport pellets 42 asthey are extruded from a plurality of extruders 46 operating at the sametime in the same plant or production facility.

During pneumatic conveyor operation, one or more blowers, fans, or otherair moves are operated to move air through the ductwork of the pneumaticconveyor 99 transporting pellets 42 from the pellet collector 72 of eachextruder 46 to at least one remote location. Air flowing through theductwork preferably sucks pellets 42 from at or adjacent the bottom ofthe collector 72 into one or both ducts 92, 94, including substantiallysimultaneously, transporting the pellets 42 conduit 98 to the at leastone remote location. Doing so preferably creates a pressure differentialwithin the pellet collector 72, e.g. a vacuum, which facilitates suckingpellets 42 in the collector 72 into ducts 92, 94.

Where the granular absorbent extrusion system 40 is equipped with apellet quenching apparatus 48, the pellet quenching apparatus 48 andpneumatic conveyor 99 can form a push-pull extruded pellet transportsystem 101 with extruded gas delivered into the quenching chamber 45,preferably introduced into the knife cage 56, at a positive pressure,i.e., pressure greater than ambient pressure, and air sucked from thepellet collector 72 via ducts 92 and/or 94 at a negative pressure, i.e.pressure less than ambient pressure. In such a push-pull pellettransport system 101, quenching air gas flow transports extruded pellets42 during quenching from the knife cage 56 into the collector 72 wheresuction from the pneumatic conveyor 99 draws the pellets 42 into one ofthe ducts 92, 94.

The pellet collector 72 and discharge ducts 92, 94 are anchored to abase 100 that can be carried on wheels 102 enabling the collector 72,knife cage 56, and cutter 62 to be moved away from the discharge end 50of the extruder 46 such as to move the cutter 62 away from the die 60.The pellet collector 72 preferably is fixed to the base 100 and theducts 92, 94 anchored by a generally L-shaped angle bracket 104. In apreferred embodiment, the collector 72 and ducts 92, 94 are movablycarried by a wheeled dolly 106 with the collector 72 and 92, 94 anchoredto a platform 100 of the dolly 106 enabling the collector 72, cutter 62and the like to be wheeled away from the extruder 46 when desired.

The top 76 of the pellet collector 72 can include or provide a platform108 carrying the knife cage 56 and cutter motor 66. The knife cage 56can be anchored to the platform 108 such as by being removably attachedthereto by one or more fasteners, brackets, another fasteningarrangement, e.g., a hook and loop fastener arrangement, or the like.The cutter motor 66 preferably is removably anchored to the platform 108by a mounting bracket 110 removably fixed by fasteners or the like.

When the pellet collector 72 and dolly 106 are disposed in the operatingposition shown in FIG. 1, the cutter 62 is disposed against the extruderdie 60. As best shown in FIGS. 5 and 6, the cutter 62 has a plurality ofradially extending cutter arms 112 each carrying a cutting knife 114disposed in slidable contact with an axial cutting face 116 of the die60 with die 60 removably mounted in a die holder 118 secured withfasteners (not shown) to the discharge end of the extruder barrel 58.During extruder operation, rotation of the arms 112 of the cutter 62causes the cutter knives 114 to slidably engage the cutting face 116 ofthe die 60 cutting at least a plurality of pairs, i.e., at least threeof “ropes” of extrudate exiting the die openings 61 (FIG. 6) into atleast a plurality of pairs, i.e., of pellets 42 per second. Duringextruder operation, the cutter 62 preferably is rotated at a speed ofbetween 6,000 RPM and 10,000 RPM.

The extruded pellets 42 are received in an extrudate discharge chamber47 before the pellets 42 are removed or discharged from the extruder 46by being sucked or drawn from the extrudate discharge chamber 47 throughpellet discharge 74 where the pellets 42 are transported via flowing airto a location remote from the extruder 46. The pellet quenching chamber45 is formed of or includes at least part of the extrudate dischargechamber 47 and can be formed of or include the entire extrudatedischarge chamber 47. In a preferred embodiment, the extrudate dischargechamber 47 includes at least the pellet collector 72, e.g., hopper 71,and can and preferably does also include the knife cage 56. Thequenching chamber 45 includes at least the knife cage 56 and can andpreferably does also include the pellet collector 72, i.e., hopper 71.

Where the knife cage 56 and pellet collector 72 are one and the same,e.g., formed as a single unit, such a single unit defines both thequenching chamber 45 and the extrudate discharge chamber 47. Therefore,a pellet quenching apparatus 48 of the present invention contemplates anextrudate discharge chamber 47 formed of a housing or enclosuresubstantially completely enclosing the discharge end 50 of the extruder46 that functions as both the knife cage 56 and pellet collector 72,which can be a single housing or enclosure extending generallyvertically from adjacent the extruder die 60 to the pellet discharge 74used to remove pellets 42 from the extruder 46.

Where the granular absorbent extrusion system 40 is equipped with apellet quenching apparatus 48, extruded pellets 42 of granular sorbent44 having one or more of the beneficial absorption and adsorptioncharacteristics and water soluble binder adherence or clumpingproperties discussed elsewhere herein are optimized by quenching thepellets 42 upon extrusion before the pellets 42 are transported from theextruder 46. The quenching apparatus 48 includes a quenching gas supply52 that supplies quenching gas during extruder operation that istransported via the quenching gas delivery arrangement 54 to a quenchingchamber 45 that includes the knife cage 56 to rapidly cool andpreferably also dry the extruded pellets 42 before the pellets 42 aretransported from the extruder 46. Quenching chamber 45 can include thehopper 71 or pellet collector 72. In a preferred embodiment, thequenching apparatus 48 is an air quenching apparatus 48 that includes aquenching air supply 52 that supplies quenching gas in the form of airdelivered via a quenching air delivery arrangement 54 into the knifecage 56 at a high enough volumetric flow rate, low enough temperature,and low enough humidity or moisture content to air quench and preferablyalso dry the pellets 42.

In a preferred quenching apparatus embodiment, the quenching supply 52includes a pump 118 that preferably is a fan, blower, compressor orother type of air mover 120 that draws quenching air in through anintake 122 and outputs quenching air through a discharge 124 to aquenching air delivery arrangement 54 that is or includes an elongatequenching air delivery conduit 126. While the intake 122 of the airmover 120 can be in gas flow communication with a source of quenchingair (not shown), the intake 122 preferably is in gas flow communicationwith the ambient atmosphere, e.g., outside air or air outside of theextruder 46. The quenching air delivery conduit 126 can be a flexible orbendable duct having an inlet 127 in fluid-flow communication with theair mover discharge 124 at one end and an outlet 128 at an opposite endin fluid-flow communication with the atmosphere inside the quenchingchamber 45.

The outlet 128 of the quenching air delivery conduit 126 is attached tothe quenching chamber 45 forming a plenum 130 therewith such that flowof quenching air into the quenching chamber 45 positively pressurizes atleast a portion of the quenching chamber 45 to a pressure greater thanambient. In the preferred embodiment shown in FIGS. 1-6, the outlet 128of the quenching air delivery conduit 126 is attached to the top wall 73of the knife cage 56 forming plenum 130 with the knife cage 56positively pressurizing at least the atmosphere within the knife cage 56during quenching during extruder operation. In a preferred pelletquenching apparatus 48, quenching air directed from the outlet 128 ofthe quenching air delivery conduit 126 into the quenching chamber 45positively pressurizes at least that portion of the atmosphere withinthe chamber 45 contacting and surrounding the pellets 42 as they arebeing extruded from the die 60 and cut by the rotary cutter 62. Incontrast, the hopper 71 or pellet collector 72 can be negativelypressurized below ambient pressure from the suction of the air conveyor99 used to draw the extruded pellets 42 from the collector 72 into thepellet discharge 74 when removing the pellets 42 from the extruder 46.

While knife cage 56 can be of perforate construction, e.g., wire-mesh orperforate stainless steel, a preferred knife cage 56 is modified to be asubstantially gas tight headbox 59 having an imperforate top wall 73,imperforate sidewalls 75, 77, 79 and/or 81, and/or an imperforate pelletdirecting funnel 83. Such a knife cage 56, e.g. headbox 59, issubstantially gas-tight or air-tight in that it may not be completelyairtight, such as where the cutter shaft 64 and/or extruder barrel 58are received therein, but is substantially gas tight by being gas tightenough to produce a positive pressure differential with ambient pressurewithin the knife cage 56 during receipt of quenching air duringquenching pellet apparatus operation. Use of a substantially gas-tighthead box 59 that also functions as a knife cage 56 helps maintain apositive pressurization within the quenching chamber 45 while alsohelping to direct flow of quenching air therethrough into the pelletcollector 72 transporting the pellets 42 thereto preferably withoutcontacting the head box 59 or knife cage 56.

Pellet collecting hopper 71, e.g., pellet collector 72, can also be ofsubstantially gas tight construction by being formed with an imperforatetop wall 76, imperforate sidewalls 78, 80, 82 and/or 84, and/or animperforate bottom wall 86. As with the knife cage 56, e.g. headbox 59,the hopper 71 may not be completely airtight, such as due to leakagefrom where one or more of the walls 76, 78, 80, 82, 84, and/or 86 arejoined together and/or door 88, the hopper 71 is sufficiently gas tightto produce a negative pressure differential with ambient pressure duringoperation of the pneumatic conveyor 99.

As best shown in FIGS. 3-6, the outlet 128 of the quenching air deliveryconduit 126 can include a divergent or outwardly flared flow expander131 that helps distribute the flow of quenching air more uniformlythroughout the quenching chamber 45, e.g., knife cage 56, to help moreuniformly quench the pellets 42 during operation. As is best shown bythe arrows in FIGS. 3 and 4 downwardly extending from the quenching airdelivery conduit outlet 128, flow of quenching air is directed not onlyon pellets 42 as they are being extruded from the die 60 and cut by therotary cutter 62, but quenching air also is directed on the pellets 42after they have been by the cutter 62 while the extruded pellets 42still reside in the quenching chamber 45, e.g., knife cage 56. Moreuniform distribution of the quenching air within the quenching chamber45 by using such a flow expander 131 more uniformly quenches the pellets42 while also providing at least some of the benefits of an air knife byadvantageously preventing pellets 42 from adhering to any part of theknife cage 56, die 60, rotary cutter 62, and/or cutter shaft 64 duringextruder operation.

In a preferred embodiment, the outlet 128 of the quenching air deliveryconduit 126 axially overlaps the die 60 and rotary cutter 62, and canaxially overlap part of the cutter shaft 64 and/or extruder barrel 58,including part of the free end or discharge and of the barrel 58, e.g.,die holder 118. If desired, the quenching air delivery conduit outlet128 can be oriented generally perpendicular to the axis of the cuttershaft 64 and generally perpendicular to the direction pellets 42 flowout of the die openings 61 during extrusion to help direct each pellet42 substantially immediately upon being cut from the die 60 by thecutter 62 toward the knife cage exit opening 70 and/or pellet collectorinlet opening 70 to minimize residency time in the knife cage 56 and/orpellet collector 72 before being transported out the pellet discharge74.

In one preferred embodiment, the quenching air delivery conduit outlet128 is generally in line with the knife cage exit opening 70 and/orpellet collector inlet opening 70 so that pellets 42 become entrained inthe flow of quenching air during pellet quenching relatively rapidlytransporting the pellets 42 from the knife cage 56 into the pelletcollector 72. As is best shown in FIG. 4, outlet 128 is in line with thedie 60, rotary cutter 62, and opening 70 between the knife cage 56 andpellet collector 72 with flow of quenching air from the outlet 128 beingdirected generally downwardly towards the die 60, cutter 62 and opening70. During pellet quenching apparatus operation, a stream or flow ofquenching air, as indicated by generally downwardly extendingun-numbered quenching air flow arrows in FIGS. 3, 4 and 6, dischargedfrom the quenching air delivery conduit outlet 128 impinges against thepellets 42 as the pellets 42 are being cut and separated from theextruder die 60 directing the extruded pellets 42 while quenching themfrom the knife cage 56 through opening 70 into the pellet collector 72without contacting the knife cage 56. As is best shown in FIGS. 3, 4 and6, the flow of quenching air discharged from outlet 128 is generallyperpendicular an axis of rotation or lengthwise extent of the cuttershaft 64 and generally parallel with the axial face 116 of the extruderdie 60 helping to substantially immediately direct pellets 42 as theyare cut from the die 60 by the knives 114 of the cutter 62 free or clearof the die 60 and cutter 62 preventing any portion of any pellet 42 fromsticking thereon or gumming either the die 60 or cutter 62.

This not only helps facilitate longer and more complete pelletquenching, the director in line flow arrangement of the quenching airdelivery conduit 126 with opening 70 (and die 60 and cutter 62)advantageously enables extruder throughput to be increased allowing morepellets 42 to be extruded per second of extruder operation. This alsonot only prevents gumming up of the rotary cutter 62, the inlinearrangement of the quenching air delivery conduit outlet 128, extruderdie 60, rotary cutter 62 and opening between the knife cage 56 andpellet collector 72 propels the extruded pellets 42 as the pellets 42are cut and separated from the die 60 by the rotary cutter 62 directlythrough the opening 70 into the pellet collector 72 without contactingthe knife cage 56. This advantageously minimizing and preferablysubstantially completely prevents pellet-impact induced wear and damage,particularly to the knife cage 56. Doing so also keeps the knives 114 ofthe cutter 62 cooler, which not only prevents soluble starches in theextruded pellets 42 from condensing on, coating and/or gumming them butalso advantageously extends rotary cutter knife life.

During operation of the pellet quenching apparatus 48, quenching airdelivery conduit outlet 128 directs flow of quenching air into the knifecage 56 close enough to pellets 42 being extruded from the die 60 of theextruder 46 such that quenching of the pellets 42 starts to occurimmediately upon pellet extrusion preferably even while the pellets 42are being squeezed out the extruder die openings 61. Quenching continueswhile the extruded pellets 42 reside in the knife cage 56. Where thequenching chamber 45 includes the pellet collecting hopper 71, e.g.,pellet collector 72, quenching preferably also continues while theextruded pellets 42 reside in the pellet collector 72 and preferablycontinues up until the pellets 42 are transported from the extruder 46via the pellet discharge 74.

In a preferred pellet quenching apparatus embodiment, the air mover 120preferably is a centrifugal fan or squirrel cage blower powered by anelectrical motor that preferably is at least an about ¾ horsepower motor(0.55 kw motor) and which preferably is at least a 1.2 HP motor (0.9 kwmotor) to provide air to the quenching chamber 45 at a volumetric flowrate of at least 500 cubic feet per minute (CFM) at an air temperaturesufficiently below the pellet extrusion temperature and at asufficiently low humidity, e.g., relative humidity, sufficient forpellet quenching to occur. In one embodiment, the air mover 120 is acentrifugal fan powered by at least an about ¾ HP motor (0.55 kw motor)and which preferably is at least a 1.2 HP motor (0.9 kw motor) thatdelivers air to the quenching chamber 45 having a sufficiently lowhumidity and temperature sufficiently less than the pellet extrusiontemperature at a flow rate of at least 700 CFM sufficient for pelletquenching to occur. In one preferred embodiment, the air mover 120 is acentrifugal fan powered by at least an about a 1.2 HP motor (0.9 kwmotor) and which preferably is at least a 2 HP motor (1.5 kw motor) thatdelivers air to the quenching chamber 45 having a sufficiently lowhumidity and temperature sufficiently less than the pellet extrusiontemperature at a flow rate of at least 800 CFM and preferably at least900 CFM sufficient for pellet quenching to occur. Such high volumetricflow rates of quenching air directed through the outlet 128 of thequenching air delivery conduit 126 into the quenching chamber 45produces turbulent quenching air flow inside the quenching chamber 45that causes turbulent convective cooling during pellet quenching in thequenching chamber 45.

In a preferred quenching apparatus embodiment and pellet quenchingmethod, quenching of pellets 42 extruded by the extruder 46 issubstantially completed by the time, e.g., pellet quench completiontime, the pellets 42 are removed from the extruder 46 by beingtransported from the pellet collector 72 out the pellet discharge 74 toa remote location by the pneumatic conveyor 99. While quenching of eachpellet 42 can continue while the pellet 42 is being transported via thepellet discharge 74 all the way up until the pellet 42 is delivered tothe remote location, quenching of each pellet 42 is substantiallycompleted by the time each pellet 42 is sucked out of the pelletcollector 72 into the pellet discharge 74.

In a preferred method and embodiment, quenching of each pellet 42extruded by the extruder 46 is substantially completed by a pelletquench completion time of no more than 3 seconds and preferably no morethan 2.5 seconds after the pellet 42 is extruded by the extruder 46 bybeing cut and separated from the die 60 by the rotary cutter 62. In onepreferred method and embodiment, quenching of each pellet 42 extruded bythe extruder 46 is substantially completed by a pellet quench completiontime of within about 2 seconds of the pellet 42 being extruded by theextruder 46. In one such preferred method and embodiment, quenching ofeach pellet 42 extruded by the extruder 46 is substantially completed bya pellet quench completion time that is no more than three seconds,preferably no more than two seconds, after being extruded such that eachextruded pellet 42 is substantially completely clenched by the time thepellet 42 is removed from the extruder 46 by being suctioned or vacuumedout the pellet collector 72 into the pellet discharge 74.

A granular absorbent extrusion system 40 equipped with a pelletquenching apparatus 48 and employing a method of pellet quenching duringextruder operation in accordance with the present invention quenches thepellets 42 immediately upon extrusion by rapidly reducing thetemperature of each extruded pellet 42 from a temperature of the pellet42 immediately upon extrusion when the pellet 42 is cut by the rotarycutter 62 from the die 60, i.e., initial pellet extrusion temperature,to a temperature sufficiently less than the pellet extrusion temperaturethat quenches the pellet 42 such that the as-extruded structure of theouter surface of the pellet 42, including pores, three-dimensionalsurface roughness, such as uneven surface portions, surfaceirregularities, such as protrusions, cracks, and surfacediscontinuities, such as craters and indentions, formed in the pelletouter surface, are substantially completely retained. Such a granularabsorbent extrusion system 40 having a pellet quenching apparatus 48carrying out pellet quenching during extruder operation forms extrudedpellets 42 upon quenching having at least a plurality of pores and atleast a plurality of at least one of depressions, protrusions and othersurface roughness thereby producing quenched extruded pellets 42 inaccordance with the present invention having increased pellet outersurface area. Such extruded quenched sorbent pellets 42 of the presentinvention with such increased outer surface area provides increasedabsorption and adsorption of both water and oil, e.g., water insolubleor water immiscible liquids, during sorbent use. Such extruded quenchedsorbent pellets 42 having such increased outer surface area as a resultof quenching preferably form sufficient starch-based flowable adhesivebinder when wetted during sorbent use for wetted pellets 42 to adheretogether and preferably form clumps that become substantially hard whendry.

A granular absorbent extrusion system 40 equipped with a pelletquenching apparatus 48 and carrying out pellet quenching in accordancewith the present invention during extruder operation reduces andpreferably helps prevent any further transformation of at least some ofthe starches present in the extruded pellet 42, including at least somestarches converted by being modified, preferably physically modified,during extrusion. Rapid cooling of each pellet 42 during quenchingreduces and preferably substantially completely prevents transformationof liquid soluble starches in each pellet 42 following extrusionpreventing loss or reduction of liquid soluble starches therebymaximizing the amount of liquid soluble starches in each pellet 42,including cold water soluble starches, including amylopectin cold watersoluble starch, helping to maximize liquid absorption and adsorption ofat least water and preferably both water and oil. Such rapid cooling ofeach pellet 42 during quenching preferably also reduces and preferablyalso substantially completely prevents transformation of water solublebinders in each pellet 42 following extrusion preventing loss orreduction thereof thereby maximizing the amount of liquid solublebinders in each pellet 42, including cold water soluble binders, helpingto maximize not only absorption and adsorption but also advantageouslymaximizes clumping and clump retention. Such rapid cooling of eachpellet 42 during quenching preferably also reduces and preferably alsosubstantially completely prevents transformation of converted ormodified amorphous water soluble starches into crystalline starches ineach pellet 42, e.g., by freezing the state of the amorphous watersoluble starches thereby preventing retrogradation, crystallizationand/or re-crystallization thereof, following extrusion preventing lossor reduction thereof thereby maximizing the amount of liquid solublestarches in each pellet 42, including cold water soluble starch binders,helping to maximize not only absorption and adsorption but alsoadvantageously maximizes clumping and clump retention.

A granular absorbent extrusion system 40 equipped with a pelletquenching apparatus 48 and carrying out pellet quenching in accordancewith the present invention during extruder operation rapidly solidifiesat least the outer surface of each pellet 42, if not substantiallysolidifying the entire pellet 42, during substantially simultaneousrapid cooling and drying of each pellet 42 that occurs during pelletquenching. Rapid drying of each pellet 42 that occurs during quenchingsolidifies at least the outer surface of each pellet 42 by removingmoisture from the outer pellet surface, including moisture within eachpellet 42 that vaporizes during extrusion through the die opening 61,drying and therefore hardening the outer pellet surface. Rapid coolingof each pellet 42 that occurs during quenching also can and preferablydoes solidify at least the outer surface of each pellet 42 andpreferably helps solidify at least a portion of the interior of thepellet 42 by rapidly retrograding starches, including amylose starchesconverted, including by physical modification, e.g. physically convertedor physically modified amylose starches, during pellet extrusion forminga substantially solid, relatively stiff starch matrix in the pellet 42after quenching.

Rapid drying caused by quenching advantageously also increases the rateof cooling, particularly immediately upon extrusion of each pellet 42upon cutting of the pellet 42 from the die 60 by the rotary cutter 62,by causing evaporative cooling of each pellet 42 during and immediatelyupon extrusion by speeding the rate of evaporation of moisture from eachpellet 42. Evaporative cooling occurs and preferably is increased bydrying of each pellet 42 during quenching by speeding the rate of pelletsurface evaporation and preferably also by speeding the rate ofevaporation of moisture with each pellet 42 vaporized during extrusion.

Rapid drying during quenching causes evaporative cooling thatadvantageously quickly removes moisture vaporized from the pellet 42substantially as quickly as the vaporized moisture is being expelledtherefrom thereby preventing the moisture from solubilizing and/ordissolving water soluble starches, including cold water solublestarches, thereby preventing loss thereof advantageously preserving theamount of water soluble starches that were originally formed, includingby physical conversion or modification, in each pellet 42 duringextrusion. Rapid drying during quenching causes evaporative cooling thatadvantageously quickly removes moisture vaporized from the pellet 42substantially as quickly as the vaporized moisture is being expelledtherefrom thereby preventing the moisture from altering the amorphousstate of water soluble starches, including cold water soluble starches,formed in each pellet 42 during extrusion thereby preventing lossthereof advantageously preserving the amount of water soluble starches,including cold water soluble starch binders, that were originally formedin each pellet 42, including by physical conversion or modification,during extrusion. Rapid drying during quenching causes evaporativecooling that advantageously quickly removes moisture vaporized from thepellet 42 substantially as quickly as the vaporized moisture is beingexpelled therefrom thereby preventing the moisture from altering theamorphous state of amorphous amylopectin cold water soluble starches,including amorphous amylopectin cold water soluble starch binders,formed in each pellet 42 during extrusion thereby preventing lossthereof advantageously preserving the amount of water soluble starches,including cold water soluble starch binders, that were originally formedin each pellet 42, including by physical conversion or modification,during extrusion by preventing their crystallization,re-crystallization, melting, further melting and/or degradation.

A granular absorbent extrusion system 40 equipped with a pelletquenching apparatus 48 and carrying out pellet quenching in accordancewith the present invention during extruder operation preserves the sizeof each extruded pellet 42 by drying each pellet 42 beginningimmediately while each pellet 42 is being squeezed out of the die holes61 and following extrusion of each pellet 42 by the cutter 62 cuttingthe pellet 42 from the die 60 preventing pellet shrinkage that normallyoccurs during and immediately following extrusion. A method of pelletquenching using a pellet quenching apparatus 48 in accordance with thepresent invention maintains pellet size by substantially completelypreventing pellet shrinkage of each pellet 42 extruded from extruder 46producing extruded quenched pellets 42 having substantially the samesize during sorbent use as when extruded from the die 60 and cut byrotary cutter 62.

A preferred method of pellet quenching using a pellet quenchingapparatus 48 in accordance with the present invention maintains pelletsize by substantially completely preventing pellet shrinkage of eachpellet 42 that ordinarily occurs during extrusion producing extrudedquenched pellets 42 that each shrink less than 25% from the originalsize of the pellet 42 when extruded out die opening 61 and cut by rotarycutter 62. Another preferred method of pellet quenching using a pelletquenching apparatus 48 in accordance with the present inventionmaintains pellet size by substantially completely preventing pelletshrinkage of each pellet 42 that ordinarily occurs during extrusionproducing extruded quenched pellets 42 that each shrink less than 20%from the original size of the pellet 42 when extruded out die opening 61and cut by rotary cutter 62. Still another preferred method of pelletquenching using a pellet quenching apparatus 48 in accordance with thepresent invention maintains pellet size by substantially completelypreventing pellet shrinkage of each pellet 42 that ordinarily occursduring extrusion producing extruded quenched pellets 42 that each shrinkless than 15% from the original size of the pellet 42 when extruded outdie opening 61 and cut by rotary cutter 62. A further preferred methodof pellet quenching using a pellet quenching apparatus 48 in accordancewith the present invention maintains pellet size by substantiallycompletely preventing pellet shrinkage of each pellet 42 that ordinarilyoccurs during extrusion producing extruded quenched pellets 42 that eachshrink less than 10% from the original size of the pellet 42 whenextruded out die opening 61 and cut by rotary cutter 62. A still furtherpreferred method of pellet quenching using a pellet quenching apparatus48 in accordance with the present invention maintains pellet size bysubstantially completely preventing pellet shrinkage of each pellet 42that ordinarily occurs during extrusion producing extruded quenchedpellets 42 that each shrink less than 7% from the original size of thepellet 42 when extruded out die opening 61 and cut by rotary cutter 62.Yet another preferred method of pellet quenching using a pelletquenching apparatus 48 in accordance with the present inventionmaintains pellet size by substantially completely preventing pelletshrinkage of each pellet 42 that ordinarily occurs during extrusionproducing extruded quenched pellets 42 that each shrink less than 5%from the original size of the pellet 42 when extruded out die opening 61and cut by rotary cutter 62.

A granular absorbent extrusion system 40 equipped with a pelletquenching apparatus 48 and carrying out pellet quenching in accordancewith the present invention during extruder operation preserves the bulkdensity of each extruded pellet 42 by drying each pellet 42 beginningimmediately while each pellet 42 is being squeezed out of the die holes61 as well as immediately following extrusion of each pellet 42 by thecutter 62 cutting the pellet 42 from the die 60 preventing pelletdensity increases that normally occurs during and immediately followingextrusion. A method of pellet quenching using a pellet quenchingapparatus 48 in accordance with the present invention maintains pelletdensity by substantially completely preventing pellet shrinkage of eachpellet 42 extruded from extruder 46 producing extruded quenched pellets42 having substantially the same size during sorbent use as whenextruded from the die 60 and cut by rotary cutter 62.

A preferred method of pellet quenching using a pellet quenchingapparatus 48 in accordance with the present invention maintains pelletdensity by substantially completely preventing increases in density ofeach pellet 42 that ordinarily occurs during extrusion producingextruded quenched pellets 42 that each increase in density less than 25%from the original density of the pellet 42 when extruded out die opening61 and cut by rotary cutter 62. Another preferred method of pelletquenching using a pellet quenching apparatus 48 in accordance with thepresent invention maintains pellet density by substantially completelypreventing increases in density of each pellet 42 that ordinarily occursduring extrusion producing extruded quenched pellets 42 that eachincrease in density less than 20% from the original density of thepellet 42 when extruded out die opening 61 and cut by rotary cutter 62.Still another preferred method of pellet quenching using a pelletquenching apparatus 48 in accordance with the present inventionmaintains pellet density by substantially completely preventingincreases in density of each pellet 42 that ordinarily occurs duringextrusion producing extruded quenched pellets 42 that each increase indensity less than 15% from the original density of the pellet 42 whenextruded out die opening 61 and cut by rotary cutter 62. A furtherpreferred method of pellet quenching using a pellet quenching apparatus48 in accordance with the present invention maintains pellet density bysubstantially completely preventing increases in density of each pellet42 that ordinarily occurs during extrusion producing extruded quenchedpellets 42 that each increase in density less than 10% from the originaldensity of the pellet 42 when extruded out die opening 61 and cut byrotary cutter 62. A still further preferred method of pellet quenchingusing a pellet quenching apparatus 48 in accordance with the presentinvention maintains pellet density by substantially completelypreventing increases in density of each pellet 42 that ordinarily occursduring extrusion producing extruded quenched pellets 42 that eachincrease in density less than 7% from the original density of the pellet42 when extruded out die opening 61 and cut by rotary cutter 62. Yetanother preferred method of pellet quenching using a pellet quenchingapparatus 48 in accordance with the present invention maintains pelletdensity by substantially completely preventing increases in density ofeach pellet 42 that ordinarily occurs during extrusion producingextruded quenched pellets 42 that each increase in density less than 5%from the original density of the pellet 42 when extruded out die opening61 and cut by rotary cutter 62.

Drying of each pellet 42 during quenching advantageously prevents pelletshrinkage and pellet densification that ordinarily occurs during andfollowing extrusion by rapidly removing moisture from each pellet 42upon and immediately following extrusion. Pellet shrinkage anddensification is prevented by flash drying each pellet 42 during andimmediately following extrusion thereby removing moisture from thepellet 42 that ordinarily would dissolve or solubilize water-solublestarches, including cold water-soluble starches, including amorphouscold water soluble amylopectin starch binders, in each pellet 42 andshrink each pellet 42 by causing at least a portion of each pellet 42 tocollapse. Preventing post-extrusion moisture in each pellet 42 fromdissolving and collapsing each pellet 42 during and immediatelyfollowing extrusion advantageously helps to preserve the amount ofwater-soluble starches, including cold water-soluble starches, includingamorphous cold water soluble amylopectin starch binders, formed in eachpellet 42 by extrusion thereby helping to maximize the absorption,adsorption and clumping ability of the extruded quenched pellets 42during sorbent use.

Drying of each pellet 42 during quenching also is accomplished byreducing the moisture content or relative humidity in the atmospherewithin the quenching chamber 45 by introducing quenching air into thequenching chamber 45 having a sufficiently low temperature and moisturecontent, e.g. relative humidity, at a high enough volumetric flow ratethat condensation of moisture on each pellet 42 after extrusion issubstantially completely prevented. Preventing post-extrusion moisturecondensation on each pellet further advantageously helps to preserve theamount of water-soluble starches, including cold water-soluble starches,preferably amorphous cold water soluble amylopectin starch binders,formed in each pellet 42 by extrusion thereby helping to maximize theabsorption, adsorption and clumping ability of the extruded quenchedpellets 42 during sorbent use.

As a result, a method of extruding granular sorbent 42 of the presentinvention using a granular sorbent extrusion system 40 equipped with apellet quenching apparatus 48 constructed in accordance with the presentinvention carrying out a method of granular sorbent pellet quenching ofthe invention has many benefits including producing extruded quenchedpellets 42 of granular sorbent 44 of the present invention havinggreater pellet crush strength, increased pellet hardness, increasedliquid absorption, e.g., increased water and/or oil absorption,increased liquid adsorption, e.g., increased water and/or oiladsorption, lower shrinkage and lower density, increased clumpingability, increased clump retention, and/or increased clump hardnessand/or clump crush strength after clump drying. Such extruded granularsorbent 44 of the invention formed of pellets 42 extruded and quenchedusing a granular sorbent extrusion system 40 equipped with a pelletquenching apparatus 48 in accordance with the present inventionadvantageously produces extruded quenched pellets 42 well suited for usein water sorbent applications, preferably animal, cat or kitty litter.Such extruded granular sorbent 44 of the invention formed of pellets 42extruded and quenched using a granular sorbent extrusion system 40equipped with a pellet quenching apparatus 48 in accordance with thepresent invention advantageously produces extruded quenched pellets 42possessing both oleophilic and hydrophobic characteristics making itwell suited for use in oil or water insoluble/immiscible liquid sorbentapplications, preferably oil sorbent, oil absorbent, or oil dry.

Such extruded granular sorbent 44 of the invention formed of pellets 42extruded and quenched using a granular sorbent extrusion system 40equipped with a pellet quenching apparatus 48 in accordance with thepresent invention advantageously produces extruded quenched pellets 42that are oleophilic, hydrophobic and hydrophilic making the pellets 42well suited for dual use in both (a) water soluble liquid absorbentapplications and (b) oil or water insoluble/immiscible liquid sorbentapplications. Such granular sorbent 44 formed of such extruded andquenched pellets 42 of oleophilic, hydrophobic and hydrophilicconstruction can be used not only as pet or animal litter but also asoil absorbent or oil dry.

A granular absorbent extrusion system 40 and method of the presentinvention preferably not only quenches each pellet 42 immediately uponextrusion but also flash dries each pellet 42 immediately upon extrusionthereby preventing moisture-related changes to the pellets 42 fromoccurring right after extrusion. In a preferred system and method, eachpellet 42 is fluid quenched, preferably gas quenched, immediately uponextrusion by introducing gas into atmosphere surrounding pellets 42 asthey are extruded where the quenching gas has a temperature and moisturecontent, e.g., humidity, far enough below the temperature and humidityof the surrounding atmosphere to prevent moisture related changes fromoccurring to the extruded pellet 42. In one system and method, asufficient volume of quenching gas, preferably air, is introduced intothe surrounding atmosphere in which pellets 42 are discharged from theextruder 44 with the quenching air having a low enough temperature andhumidity to dehumidify moisture in the surrounding atmosphere from watervaporized out each pellet 42 during extrusion enough to prevent moisturein the surrounding atmosphere from subsequently condensing on thepellets 42. Drying of each pellet 42, preferably flash drying,preferably also occurs during quenching as a result of moisture on theouter pellet surface being evaporated advantageously reducing pelletmoisture content.

Such a volume of quenching air introduced into the surroundingatmosphere at such a sufficiently low temperature and humidity toprevent extruded pellets 42 from becoming wetted by moisturecondensation advantageously reduces and preferably substantiallycompletely prevents pellet shrinkage that ordinarily occurs immediatelyafter extrusion. Doing so also prevents consumption of water solubles ineach pellet 42 that ordinarily dissolve or solubilize from moisturecondensation thereby advantageously preserving the amount of watersolubles in each pellet 42 after extrusion. This advantageously not onlyprevents loss of water soluble binder by preventing consumption due tocondensation induced wetting and solubilization, it also advantageouslyhelps maximize pellet absorption by preventing liquid absorbent solublesfrom similarly being consumed by condensation induced wetting andsolubilization.

During quenching apparatus operation, air having a moisture content orhumidity, e.g., relative humidity, and temperature sufficient far enoughbelow one or both of the pellet extrusion temperature and thetemperature of the extruder 46 at the die 60, e.g., extrudertemperature, is delivered by the air mover 120 via the duct 126 throughoutlet 128 into the knife cage 56 at a sufficiently high enoughvolumetric flow rate to quench a plurality of pairs, i.e., at leastthree, of pellets 42 substantially simultaneously as the plurality ofpairs of pellets 42 are substantially simultaneously being extruded orsqueezed out the openings 61 in the extruder die 60. Air having such amoisture content or humidity, e.g., relative humidity, and temperaturesufficiently far enough below one or both of the pellet extrusiontemperature and extruder temperature is delivered to the knife cage 56at a sufficiently high enough flow rate to continue quenching theplurality of pairs of pellets 42 after being squeezed out the die 60including continuing quenching during at least a portion of the time theplurality of pairs of pellets 42 reside in the knife cage 56.Preferably, air having such a moisture content or humidity, e.g.,relative humidity, and temperature sufficiently far enough below one orboth of the pellet extrusion temperature and extruder temperature isdelivered to the knife cage 56 at a sufficiently high enough flow rateto continue quenching the plurality of pairs of pellets 42 even duringthe entire time the plurality of pairs of pellets 42 reside in the knifecage 56 before being received by the pellet collector 72 of the extruder46. Air having such a moisture content or humidity, e.g., relativehumidity, and temperature sufficiently far enough below one or both ofthe pellet extrusion temperature and extruder temperature is deliveredto the knife cage 56 at a sufficiently high enough flow rate thatquenching of the plurality of pairs of pellets 42 can continue while thepellets 42 reside in the pellet collector 72 of the extruder 46 even upto the time the pellets 42 are transported from the collector 72 bydelivery duct 98.

Quenching air having a temperature less than at least one of the pelletextrusion temperature, e.g., pellet exit temperature at the head of thedie 60, and extruder temperature and having a humidity less than thehumidity of the atmosphere within the knife cage 56 is discharged fromthe outlet 128 of the quenching air delivery duct 126 at a high enoughflow rate into the knife cage 56 to perform pellet quenching by causingthe temperature of each pellet 42 to drop from a temperature of thepellet 42 as the pellet 42 is being extruded out the die opening 61,e.g., pellet exit temperature at the head of the die 60, to a coolerquenched pellet temperature that is at least 15 degrees Celsius lessthan the pellet extrusion temperature thereby rapidly cooling eachpellet 42 to a quenched pellet temperature that preferably is no higherthan 60 degrees Celsius above ambient temperature before each pellet 42removed from the quenching chamber 45 and enters the delivery duct 98.In a preferred quenching apparatus embodiment and quenching method, airhaving a temperature less than at least one of the pellet extrusiontemperature and extruder temperature and having a humidity less than thehumidity of the atmosphere within the knife cage 56 is introduced intothe knife cage 56 at a high enough flow rate to perform pellet quenchingby causing the temperature of each pellet 42 to drop from its pelletsextrusion temperature to a quenched pellet temperature that is at least20 degrees Celsius less than the pellet extrusion temperature therebyrapidly cooling each pellet 42 to a quenched pellet temperature thatpreferably is no higher than 55 degrees above ambient temperature beforeeach pellet 42 enters the delivery duct 98. In another preferredembodiment and method, air having a temperature less than at least oneof the pellet extrusion temperature and extruder temperature and havinga humidity less than the humidity of the atmosphere within the knifecage 56 is introduced into the knife cage 56 at a high enough flow rateto perform pellet quenching by causing the temperature of each pellet 42to drop from its pellets extrusion temperature to a quenched pellettemperature that is at least 25 degrees Celsius less than the pelletextrusion temperature thereby rapidly cooling each pellet 42 to aquenched pellet temperature that preferably is no higher than 50 degreesabove ambient temperature before each pellet 42 enters the delivery duct98. In still another preferred embodiment and method, air having atemperature less than at least one of the pellet extrusion temperatureand extruder temperature and having a humidity less than the humidity ofthe atmosphere within the knife cage 56 is introduced into the knifecage 56 at a high enough flow rate to perform pellet quenching bycausing the temperature of each pellet 42 to drop from its pelletsextrusion temperature to a quenched pellet temperature that is at least30 degrees Celsius less than the pellet extrusion temperature therebyrapidly cooling each pellet 42 to a quenched pellet temperature thatpreferably is no higher than about 45 degrees above ambient temperaturebefore each pellet 42 enters the delivery duct 98. Ambient temperatureis defined as the temperature of the air of the ambient atmospheredisposed outside the knife cage 56 and pellet collector 72 of theextruder 46 (and disposed outside the extruder 46) measured at adistance of at least eight feet away from the knife cage 56 andcollector 72.

A pellet quenching apparatus 48, pellet quenching method, and extrudedgranular sorbent 44 in accordance with the present invention airquenches each pellet 42 upon extrusion rapidly cooling each extrudedpellet 42 as described herein, including as described in the precedingparagraph, preserving liquid soluble starches, preferably cold watersoluble starches, including cold water soluble binder, formed in eachpellet 42 during extrusion preventing loss of water solubility andpreventing loss of absorptivity in each pellet 42 that normally occursupon extrusion if not air quenched such that after quenching theextruded pellets 42 each have at least 10%, preferably at least 12%,water solubles by uncoated pellet weight and which each also have awater absorptivity of at least three times, preferably at least fourtimes, by uncoated pellet weight. Rapid cooling by air quenching “sets”or freezes the state of the water solubles in each extruded pellet 42such that the air quenched pellets 42 extruded from starch-containingadmixture as disclosed herein at extruder operating parameters as alsodisclosed herein produces granular sorbent 44 of the present inventionhaving at least 10%, preferably at least 12%, water soluble starches ineach pellet 42 by uncoated pellet weight thereby containing enough watersoluble binder by uncoated pellet weight for pellets 42 wetted withwater for sufficient water soluble binder to dissolve, e.g., solubilize,and flow in between adjacent pellets 42 “self-clumping” pellets 42forming a clump of at least a plurality of pairs of pellets 42 gluedtogether by the binder that becomes substantially hard when the clump isdried.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is dried to a moisturecontent of no greater than 15% and preferably between 6%-12% moisture bydry or dried clump weight when substantially dry. In at least onepreferred quenching method and embodiment, each clump formed of quenchedextruded sorbent pellets 42 of the present invention has a clump crushstrength of at least 30 PSI and a clump retention or clump retentionrate of at least 97%, preferably at least 99%, when the clump issubstantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially.

A preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 10% water soluble binder, including cold water soluble binder, byuncoated pellet weight and also has a water absorptivity of at leastthree times uncoated pellet weight. Rapid cooling by air quenching“sets” or freezes the state of the water soluble binder in each pellet42 upon extrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 10% starch-based water soluble binderin each pellet 42 by uncoated pellet weight thereby containing enoughwater soluble binder by uncoated pellet weight for pellets 42 wettedwith water to dissolve and flow sufficient water soluble binder betweenadjacent pellets 42 forming a clump of at least a plurality of pairs ofpellets 42 glued together by the binder that becomes a substantiallyhard clump when substantially dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Another preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 10% cold water soluble binder by uncoated pellet weight and alsohas a water absorptivity of at least three times uncoated pellet weight.Rapid cooling by air quenching “sets” or freezes the state of the coldwater soluble binder in each pellet 42 upon extrusion such that the airquenched pellets 42 extruded from starch-containing admixture asdisclosed herein at extruder operating parameters as also disclosedherein produces granular sorbent 44 of the present invention having atleast 10% cold water soluble binder in each pellet 42 by uncoated pelletweight thereby containing enough cold water soluble binder for pellets42 wetted with water to solubilize or dissolve sufficient water solublebinder that flows between adjacent pellets 42 in the form of flowablestarch-based adhesive clumping pellets 42 together producing a clumpformed of a plurality of pairs of pellets 42 glued together by theflowable starch-based adhesive that becomes substantially hard when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Still another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 15% water solubles content, e.g., water soluble starches,by uncoated pellet weight and also has a water absorptivity of at leastthree times uncoated pellet weight. Rapid cooling by air quenching“sets” or freezes the state of the water solubles in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 15% water solubles, including watersoluble binder, in each pellet 42 by uncoated pellet weight therebycontaining enough water soluble binder by uncoated pellet weight forpellets 42 wetted with water to dissolve and flow sufficient watersoluble binder between adjacent pellets 42 forming a clump of at least aplurality of pairs of pellets 42 glued together by the binder thatbecomes a substantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is dried to a moisture content of no greater than 15% andpreferably between 6%-12% moisture when the clump is substantially dry.In one such preferred quenching method and embodiment, each clump formedof such quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 40 PSI and a clump retention orclump retention rate of at least 90%, preferably at least 95%, when theclump is substantially dry. In another preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 50PSI and a clump retention or clump retention rate of at least 95%,preferably at least 97%, when the clump is substantially dry. In afurther preferred method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 65 PSI and a clump retention or clumpretention rate of at least 97%, preferably at least 99%, when the clumpis substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 15% water soluble binder, including cold water soluble binder, byuncoated pellet weight and also has a water absorptivity of at leastthree times uncoated pellet weight. Rapid cooling by air quenching“sets” or freezes the state of the water soluble binder in each pellet42 upon extrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 15% water soluble binder in eachpellet 42 by uncoated pellet weight thereby containing enough watersoluble binder by uncoated pellet weight for pellets 42 wetted withwater to dissolve and flow sufficient water soluble binder betweenadjacent pellets 42 forming a clump of at least a plurality of pairs ofpellets 42 glued together by the binder that becomes a substantiallyhard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 15% cold water soluble binder by uncoated pellet weight andalso has a water absorptivity of at least three times uncoated pelletweight. Rapid cooling by air quenching “sets” or freezes the state ofthe cold water soluble binder in each pellet 42 upon extrusion such thatthe air quenched pellets 42 extruded from starch-containing admixture asdisclosed herein at extruder operating parameters as also disclosedherein produces granular sorbent 44 of the present invention having atleast 15% cold water soluble binder in each pellet 42 by uncoated pelletweight thereby containing enough cold water soluble binder for pellets42 wetted with water to dissolve sufficient cold water soluble binderthat flows between adjacent pellets 42 clumping pellets 42 togetherproducing a clump formed of a plurality of pairs of pellets 42 gluedtogether by the binder that becomes substantially hard when the clump isdry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Still yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 20% water solubles content, e.g., water soluble starches,by uncoated pellet weight and also has a water absorptivity of at leastfour and a half times uncoated pellet weight. Rapid cooling by airquenching “sets” or freezes the state of the water solubles in eachpellet 42 upon extrusion such that the air quenched pellets 42 extrudedfrom starch-containing admixture as disclosed herein at extruderoperating parameters as also disclosed herein produces granular sorbent44 of the present invention having at least 20% water solubles,including water soluble binder, in each pellet 42 by uncoated pelletweight thereby containing enough water soluble binder by uncoated pelletweight for pellets 42 wetted with water to dissolve and flow sufficientwater soluble binder between adjacent pellets 42 forming a clump of atleast a plurality of pairs of pellets 42 glued together by the binderthat becomes a substantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is dried to a moisturecontent of no greater than 15% and preferably between 6%-12% moisture bydry or dried clump weight. In at least one preferred quenching methodand embodiment, each clump formed of quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 30PSI and a clump retention or clump retention rate of at least 97%,preferably at least 99%, when the clump is substantially dry. In onesuch preferred quenching method and embodiment, each clump formed ofsuch quenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 40 PSI and a clump retention or clumpretention rate of at least 90%, preferably at least 95%, when the clumpis substantially dry. In another preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 50PSI and a clump retention or clump retention rate of at least 95%,preferably at least 97%, when the clump is substantially dry. In afurther preferred method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 65 PSI and a clump retention or clumpretention rate of at least 97%, preferably at least 99%, when the clumpis substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 20% starch-based water soluble binder, including starch-based coldwater soluble binder, by uncoated pellet weight and also has a waterabsorptivity of at least four times uncoated pellet weight. Rapidcooling by air quenching “sets” or freezes the state of the watersoluble binder in each pellet 42 upon extrusion such that the airquenched pellets 42 extruded from starch-containing admixture asdisclosed herein at extruder operating parameters as also disclosedherein produces granular sorbent 44 of the present invention having atleast 20% starch-based water soluble binder in each pellet 42 byuncoated pellet weight thereby containing enough water soluble binder byuncoated pellet weight for pellets 42 wetted with water to dissolve andflow sufficient water soluble binder in the form of starch-basedflowable adhesive between adjacent pellets 42 forming a clump of atleast a plurality of pairs of pellets 42 glued together by thestarch-based flowable adhesive that becomes a substantially hard clumpwhen dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 20% starch-based cold water soluble binder by uncoatedpellet weight and also has a water absorptivity of at least three timesuncoated pellet weight. Rapid cooling by air quenching “sets” or freezesthe state of the cold water soluble binder in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 20% starch-based cold water solublebinder in each pellet 42 by uncoated pellet weight thereby containingenough starch-based cold water soluble binder for pellets 42 wetted withwater to dissolve sufficient starch-based cold water soluble binder thatflows between adjacent pellets 42 clumping pellets 42 together producinga clump formed of a plurality of pairs of pellets 42 glued together bythe binder that becomes substantially hard when the clump is dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Yet still another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 25% water solubles content, e.g., water soluble starches,by uncoated pellet weight and also has a water absorptivity of at leastfour times uncoated pellet weight. Rapid cooling by air quenching “sets”or freezes the state of the water solubles in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 25% water solubles, including watersoluble binder, in each pellet 42 by uncoated pellet weight therebycontaining enough water soluble binder by uncoated pellet weight forpellets 42 wetted with water to dissolve and flow sufficient watersoluble binder between adjacent pellets 42 forming a clump of at least aplurality of pairs of pellets 42 glued together by the binder thatbecomes a substantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 25% water soluble binder, including cold water soluble binder, byuncoated pellet weight and also has a water absorptivity of at leastfour times uncoated pellet weight. Rapid cooling by air quenching “sets”or freezes the state of the water soluble binder in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 25% water soluble binder in eachpellet 42 by uncoated pellet weight thereby containing enough watersoluble binder by uncoated pellet weight for pellets 42 wetted withwater to dissolve and flow sufficient water soluble binder betweenadjacent pellets 42 forming a clump of at least a plurality of pairs ofpellets 42 glued together by the binder that becomes a substantiallyhard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 25% cold water soluble binder by uncoated pellet weight andalso has a water absorptivity of at least three times uncoated pelletweight. Rapid cooling by air quenching “sets” or freezes the state ofthe cold water soluble binder in each pellet 42 upon extrusion such thatthe air quenched pellets 42 extruded from starch-containing admixture asdisclosed herein at extruder operating parameters as also disclosedherein produces granular sorbent 44 of the present invention having atleast 25% cold water soluble binder in each pellet 42 by uncoated pelletweight thereby containing enough cold water soluble binder for pellets42 wetted with water to dissolve sufficient cold water soluble binderthat flows between adjacent pellets 42 clumping pellets 42 togetherproducing a clump formed of a plurality of pairs of pellets 42 gluedtogether by the binder that becomes substantially hard when the clump isdry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Another preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 30% water solubles content, e.g., water soluble starches, byuncoated pellet weight and also has a water absorptivity of at leastfour times uncoated pellet weight. Rapid cooling by air quenching “sets”or freezes the state of the water solubles in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 30% water solubles, including watersoluble binder, in each pellet 42 by uncoated pellet weight therebycontaining enough water soluble binder by uncoated pellet weight forpellets 42 wetted with water to dissolve and flow sufficient watersoluble binder between adjacent pellets 42 forming a clump of at least aplurality of pairs of pellets 42 glued together by the binder thatbecomes a substantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 30% water soluble binder, including cold water soluble binder, byuncoated pellet weight and also has a water absorptivity of at leastthree and a half times uncoated pellet weight. Rapid cooling by airquenching “sets” or freezes the state of the water soluble binder ineach pellet 42 upon extrusion such that the air quenched pellets 42extruded from starch-containing admixture as disclosed herein atextruder operating parameters as also disclosed herein produces granularsorbent 44 of the present invention having at least 30% water solublebinder in each pellet 42 by uncoated pellet weight thereby containingenough water soluble binder by uncoated pellet weight for pellets 42wetted with water to dissolve and flow sufficient water soluble binderbetween adjacent pellets 42 forming a clump of at least a plurality ofpairs of pellets 42 glued together by the binder that becomes asubstantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry bydry or dried clump weight. In at least one preferred quenching methodand embodiment, each clump formed of quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 30PSI and a clump retention or clump retention rate of at least 97%,preferably at least 99%, when the clump is substantially dry. In onesuch preferred quenching method and embodiment, each clump formed ofsuch quenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 40 PSI and a clump retention or clumpretention rate of at least 90%, preferably at least 95%, when the clumpis substantially dry. In another preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 50PSI and a clump retention or clump retention rate of at least 95%,preferably at least 97%, when the clump is substantially dry. In afurther preferred method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 65 PSI and a clump retention or clumpretention rate of at least 97%, preferably at least 99%, when the clumpis substantially dry.

Yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 30% cold water soluble binder by uncoated pellet weight andalso has a water absorptivity of at least three times uncoated pelletweight. Rapid cooling by air quenching “sets” or freezes the state ofthe cold water soluble binder in each pellet 42 upon extrusion such thatthe air quenched pellets 42 extruded from starch-containing admixture asdisclosed herein at extruder operating parameters as also disclosedherein produces granular sorbent 44 of the present invention having atleast 30% cold water soluble binder in each pellet 42 by uncoated pelletweight thereby containing enough cold water soluble binder for pellets42 wetted with water to dissolve sufficient cold water soluble binderthat flows between adjacent pellets 42 clumping pellets 42 togetherproducing a clump formed of a plurality of pairs of pellets 42 gluedtogether by the binder that becomes substantially hard when the clump isdry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 40% water solubles content, e.g., water soluble starches, byuncoated pellet weight and also has a water absorptivity of at leastfour and a half times uncoated pellet weight. Rapid cooling by airquenching “sets” or freezes the state of the water solubles in eachpellet 42 upon extrusion such that the air quenched pellets 42 extrudedfrom starch-containing admixture as disclosed herein at extruderoperating parameters as also disclosed herein produces granular sorbent44 of the present invention having at least 40% water solubles,including water soluble binder, in each pellet 42 by uncoated pelletweight thereby containing enough water soluble binder by uncoated pelletweight for pellets 42 wetted with water to dissolve and flow sufficientwater soluble binder between adjacent pellets 42 forming a clump of atleast a plurality of pairs of pellets 42 glued together by the binderthat becomes a substantially hard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

A further preferred granular sorbent, method of making granular sorbent,quenching apparatus 48, and pellet quenching method of the presentinvention results in each pellet 42 being air quenched upon extrusionrapidly cooling each extruded pellet 42 as described herein, includingas described hereinabove, preserving water solubles and water absorptionsuch that each air quenched pellet 42 of granular sorbent 44 has atleast 35% water soluble binder, including cold water soluble binder, byuncoated pellet weight and also has a water absorptivity of at leastfour times uncoated pellet weight. Rapid cooling by air quenching “sets”or freezes the state of the water soluble binder in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 35% water soluble binder in eachpellet 42 by uncoated pellet weight thereby containing enough watersoluble binder by uncoated pellet weight for pellets 42 wetted withwater to dissolve and flow sufficient water soluble binder betweenadjacent pellets 42 forming a clump of at least a plurality of pairs ofpellets 42 glued together by the binder that becomes a substantiallyhard clump when dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

Yet another preferred granular sorbent, method of making granularsorbent, quenching apparatus 48, and pellet quenching method of thepresent invention results in each pellet 42 being air quenched uponextrusion rapidly cooling each extruded pellet 42 as described herein,including as described hereinabove, preserving water solubles and waterabsorption such that each air quenched pellet 42 of granular sorbent 44has at least 35% cold water soluble binder by uncoated pellet weight andalso has a water absorptivity of at least three and a half timesuncoated pellet weight. Rapid cooling by air quenching “sets” or freezesthe state of the cold water soluble binder in each pellet 42 uponextrusion such that the air quenched pellets 42 extruded fromstarch-containing admixture as disclosed herein at extruder operatingparameters as also disclosed herein produces granular sorbent 44 of thepresent invention having at least 35% cold water soluble binder in eachpellet 42 by uncoated pellet weight thereby containing enough cold watersoluble binder for pellets 42 wetted with water to dissolve sufficientcold water soluble binder that flows between adjacent pellets 42clumping pellets 42 together producing a clump formed of a plurality ofpairs of pellets 42 glued together by the binder that becomessubstantially hard when the clump is dry.

Each clump formed from sorbent pellets 42 extruded from astarch-containing admixture as described above that have been quenchedin accordance with the present invention has a clump crush strength ofat least 25 pounds per square inch (PSI) and a clump retention or clumpretention rate of at least 80% when the clump is substantially dry. Inat least one preferred quenching method and embodiment, each clumpformed of quenched extruded sorbent pellets 42 of the present inventionhas a clump crush strength of at least 30 PSI and a clump retention orclump retention rate of at least 97%, preferably at least 99%, when theclump is substantially dry. In one such preferred quenching method andembodiment, each clump formed of such quenched extruded sorbent pellets42 of the present invention has a clump crush strength of at least 40PSI and a clump retention or clump retention rate of at least 90%,preferably at least 95%, when the clump is substantially dry. In anotherpreferred quenching method and embodiment, each clump formed of suchquenched extruded sorbent pellets 42 of the present invention has aclump crush strength of at least 50 PSI and a clump retention or clumpretention rate of at least 95%, preferably at least 97%, when the clumpis substantially dry. In a further preferred method and embodiment, eachclump formed of such quenched extruded sorbent pellets 42 of the presentinvention has a clump crush strength of at least 65 PSI and a clumpretention or clump retention rate of at least 97%, preferably at least99%, when the clump is substantially dry.

The present invention is thereby directed to a granular absorbentextrusion system 48 for producing extruded granular sorbent 44comprising an extruder having a perforate extruder die disposed at adischarge end of the extruder from which sorbent pellets are extrudedfrom a starch-containing admixture during extruder operation. In thegranular absorbent extrusion system, the sorbent pellets are extruded bythe extruder having sufficient water soluble binder in each sorbentpellet formed from starch in the starch-containing admixture duringextrusion for a plurality of pellets wetted with water to form a clumpcontaining at least a plurality of pairs of the pellets having a clumpcrush strength of at least 25 pounds per square inch and a clumpretention rate of at least 80% when the clump is substantially dry. Eachsorbent pellet extruded from the starch-containing admixture preferablycan and does contain at least 10% water soluble starch in each sorbentpellet. Each sorbent pellet extruded from the starch-containingadmixture preferably can and does contain at least 10% cold watersoluble starch binder in each sorbent pellet. The sorbent pelletsextruded by the extruder from the starch-containing admixture eachpreferably can and do have at least 15% cold water soluble starch binderforming clumps comprised of a plurality of pairs of wetted sorbentpellets having a clump crush strength of at least 25 pounds per squareinch and a clump retention rate of at least 90% when the clump issubstantially dry. The sorbent pellets extruded by the extruder from thestarch-containing admixture each preferably can and do have at least 15%cold water soluble starch binder forming clumps comprised of a pluralityof pairs of wetted sorbent pellets having a clump crush strength of atleast 30 pounds per square inch and a clump retention rate of at least95% when the clump is substantially dry.

The granular absorbent extrusion system 48 can include a pelletquenching apparatus comprised of (i) a quenching chamber receiving thesorbent pellets as they are extruded from the extruder die, (ii) aquenching gas supply, and (ii) a quenching gas delivery conduitintroducing quenching gas into the quenching chamber quenching theextruded sorbent pellets by cooling and drying the extruded sorbentpellets. The quenching chamber comprises one of a knife cage enclosingthe extruder die and pellet collector in gas-flow communication with theknife cage, the quenching gas delivery conduit has an outlet inline withthe extruder die and an opening between the knife cage directing a flowof quenching gas inline therewith onto sorbent pellets as the sorbentpellets are extruded from the extruder die directing the extrudedsorbent pellets from the extruder die through the opening between theknife cage into the pellet collector without contacting the knife cage.The extruder 46 has a rotary cutter carried by a cutter shaft having anaxis of rotation, the rotary cutter having a plurality of pellet cuttingknives engaging an axial outer face of the extruder during extruderoperation and wherein the flow of quenching air discharged from thequenching gas delivery conduit outlet is generally perpendicular to therotational axis of the cutter shaft. The outlet of the quenching gasdelivery conduit outlet can be and preferably is generally perpendicularto the rotational axis of the cutter shaft and generally perpendicularto the axial face of the extruder die. The quenching gas deliveryconduit outlet, knife cage and pellet collector can be and preferablyare arranged generally vertically in-line with one another. The knifecage and pellet collector can be and preferably are substantiallygas-tightly or air-tightly sealed. The extruder can and preferably doeshas an extrudate discharge chamber that receives the sorbent pelletsextruded from the extruder and wherein the quenching chamber comprisesthe extrudate discharge chamber. The extrudate discharge chamber can beof substantially gas-tight or air-tight construction.

The quenching gas delivery conduit can and preferably does have anoutlet in gas-flow communication with the quenching chamber forming aplenum that is positively pressurized above ambient pressure byquenching gas introduced into the quenching chamber during pelletquenching. The quenching chamber can and preferably does have a knifecage enclosing the extruder die, the knife cage receiving sorbentpellets as the sorbent pellets are extruded from the extruder die by theextruder during extruder operation, the knife cage substantiallygas-tightly or air-tightly sealed. The sorbent pellets extruded into thequenching chamber preferably are quenched by quenching gas in thequenching chamber reducing the temperature of the sorbent pellets froman initial pellet extrusion temperature when the sorbent pellets areextruded from the extruder die to a quenched pellet temperature when thequenched extruded sorbent pellets are removed from the extruder that isat least 25 degrees Celsius less than the initial pellet extrusiontemperature.

The sorbent pellets extruded into the quenching chamber preferably arequenched by quenching gas in the quenching chamber reducing the moisturecontent of the sorbent pellets to a moisture content of no greater than18% by uncoated pellet weight when the quenched extruded sorbent pelletsare removed from the extruder. The sorbent pellets extruded into thequenching chamber are preferably quenched by quenching gas in thequenching chamber reducing the temperature of the sorbent pellets to atemperature no greater than 72 degrees Celsius and reducing the moisturecontent of the sorbent pellets to a moisture content of no greater than18% by uncoated pellet weight when the quenched extruded sorbent pelletsare removed from the extruder.

The present invention also is directed to granular absorbent extrusionsystem for producing extruded granular sorbent comprising: (a) anextruder comprising a perforate extruder die disposed at a discharge endof the extruder from which sorbent pellets are extruded during extruderoperation; and (b) a pellet quenching apparatus comprised of (i) aquenching chamber receiving the sorbent pellets as they are extrudedfrom the extruder die, (ii) a quenching gas supply, and (ii) a quenchinggas delivery conduit introducing quenching gas into the quenchingchamber quenching the extruded sorbent pellets by cooling and drying theextruded sorbent pellets. The extruder has an extrudate dischargechamber that receives the sorbent pellets extruded from the extruder andwherein the quenching chamber comprises the extrudate discharge chamber.The extrudate discharge chamber is of substantially gas-tight orair-tight construction. The quenching gas delivery conduit has an outletin gas-flow communication with the quenching chamber forming a plenumthat is positively pressurized above ambient pressure by quenching gasintroduced into the quenching chamber during pellet quenching. Thequenching chamber comprises a knife cage enclosing the extruder die, theknife cage receiving sorbent pellets as the sorbent pellets are extrudedfrom the extruder die by the extruder during extruder operation, theknife cage substantially gas-tightly or air-tightly sealed.

The quenching chamber can further include a pellet collector in gas-flowcommunication with the knife cage and wherein the quenching gas deliveryconduit outlet, extruder die, knife cage and pellet collector are inlinewith one another directing a flow of quenching gas inline therewith ontosorbent pellets extruded from the extruder die directing the extrudedsorbent pellets from the extruder die through the knife cage and intothe pellet collector without contacting the knife cage. The extruder canhave a rotary cutter carried by a cutter shaft having an axis ofrotation, the rotary cutter having a plurality of pellet cutting knivesengaging an axial outer face of the extruder during extruder operationand wherein the flow of quenching air discharged from the quenching gasdelivery conduit outlet is generally perpendicular to the rotationalaxis of the cutter shaft. The outlet of the quenching gas deliveryconduit outlet is generally perpendicular to the rotational axis of thecutter shaft and generally perpendicular to the axial face of theextruder die. The quenching gas delivery conduit outlet, knife cage andpellet collector can be and preferably are arranged generally verticallyin-line with one another. The knife cage and pellet collector aresubstantially gas-tightly or air-tightly sealed. The outlet of thequenching gas delivery conduit outlet vertically overlaps the rotarycutter, die and opening between the knife cage and pellet collectinghopper.

The present invention also is directed to method of making granularsorbent comprising: (a) providing an extruder and a starch-containingadmixture; and (b) extruding the starch-containing admixture at or above(i) an extruder temperature, and (ii) extruder pressure forming sorbentpellets extruded from the extruder each having at least 15% cold watersoluble starches by pellet weight including cold water soluble starchbinder sufficient to produce clumps each comprised of a plurality ofpairs of the adjacent sorbent pellets when the sorbent pellets formingthe clump are wetted with water. Each clump has a clump crush strengthof at least 25 pounds per square inch when the clump is substantiallydry. Each clump has a clump crush strength of at least 25 pounds persquare inch when the clump has a moisture content no greater than 15% byclump weight. Each clump has a clump crush strength of at least 25pounds per square inch when the clump has a moisture content of between6% and 12% by clump weight. Each clump has a clump crush strength of atleast 25 pounds per square inch and a clump retention rate of at least95% when the clump is substantially dry.

Each sorbent pellet has at least 10% cold water soluble starch binder byuncoated pellet weight producing clumps each formed of a plurality ofpairs of wetted pellets having a clump crush strength of at least 25pounds per square inch and a clump retention rate of at least 80% whenthe clump is substantially dry. Each sorbent pellet has at least 15%cold water soluble starch binder by uncoated pellet weight producingclumps each formed of a plurality of pairs of wetted pellets having aclump crush strength of at least 30 pounds per square inch and a clumpretention rate of at least 90% when the clump is substantially dry. Eachsorbent pellet has at least 15% cold water soluble starch binder byuncoated pellet weight producing clumps each formed of a plurality ofpairs of wetted pellets having a clump crush strength of at least 40pounds per square inch and a clump retention rate of at least 95% whenthe clump is substantially dry.

The sorbent pellets are extruded from the extruder at a pellet extrusiontemperature and comprising the further step of quenching each pellet byreducing pellet temperature to a temperature that is at least 15 degreesCelsius less than the pellet extrusion temperature by the time thesorbent pellet is removed from the extruder. Each pellet removed fromthe extruder after quenching is completed has a temperature no higherthan 83 degrees Celsius.

A quenching chamber is disposed at a discharge end of the extruder inwhich the sorbent pellets extruded from the extruder are received, thequenching chamber in fluid flow communication with a pellet dischargethat removes each pellet from the extruder when pellet quenching iscompleted. The extruder has: (a) a rotary cutter that cuts sorbentpellets discharged from an extruder die in extruding the sorbentpellets, (b) a knife cage enclosing the rotary cutter and extruder die,the knife cage forming at least part of the quenching chamber, and (c) aquenching air mover that delivers quenching air into the knife cage at asufficient volumetric flow rate, low enough temperature and low enoughhumidity to cool each sorbent pellet during quenching by at least 15degrees Celsius from the pellet extrusion temperature to a temperatureno greater than 83 degrees Celsius when quenching is completed. Theknife cage is substantially gas-tight and wherein the quenching airreceived in the knife cage pressurizes at least the knife cage aboveambient pressure. Quenching of each sorbent pellet in the quenchingchamber retrogrades amylose starch in each pellet. Quenching of eachsorbent pellet in the quenching chamber retrogrades amylose starch ineach pellet hardening each pellet. Quenching of each sorbent pellet inthe quenching chamber prevents moisture vaporizing in each pellet fromsolubilizing or dissolving water soluble starches in each pellet.Quenching of each sorbent pellet in the quenching chamber preventsmoisture vaporizing in each pellet from solubilizing or dissolving coldwater soluble starches in each pellet. Quenching of each sorbent pelletin the quenching chamber prevents moisture vaporizing in each pelletfrom solubilizing or dissolving cold water soluble starch binder in eachpellet. Quenching of each sorbent pellet in the quenching chamberprevents moisture vaporizing in each pellet from solubilizing ordissolving cold water soluble amylopectin starch binder in each pellet.Quenching of each sorbent pellet in the quenching chamber preventsmoisture vaporizing in each pellet from changing the state of amorphouswater soluble starches in each pellet. Quenching of each sorbent pelletin the quenching chamber prevents moisture vaporizing in each pelletfrom changing the state of amorphous water soluble amylopectin starchbinder in each pellet. Quenching of each sorbent pellet in the quenchingchamber prevents moisture vaporizing in each pellet from changing thestate of amorphous cold water soluble amylopectin starch binder in eachpellet.

The present invention also is directed to a method of quenching granularsorbent comprising: (a) providing an extruder and a starch-containingadmixture; (b) extruding the starch-containing admixture at or above (i)an extruder temperature, and (ii) extruder pressure forming sorbentpellets extruded from the extruder at a pellet extrusion temperaturehaving at least 10% water soluble starches by pellet weight; and (c)quenching the pellets by reducing pellet temperature to a temperaturethat is at least 15 degrees Celsius less than the pellet extrusiontemperature. In step (c) quenching of the pellets is performed for apellet quenching completion time until pellet quenching is substantiallycompleted when the pellets are removed from the extruder. The extruderpreferably further includes a pellet collector that receives the pelletsextruded by the extruder and wherein pellet quenching completion time iscompleted when the pellets are removed from the pellet collector.

Understandably, the present invention has been described above in termsof one or more preferred embodiments and methods. It is recognized thatvarious alternatives and modifications may be made to these embodimentsand methods that are within the scope of the present invention. Variousalternatives are contemplated as being within the scope of the presentinvention. It is also to be understood that, although the foregoingdescription and drawings describe and illustrate in detail one or morepreferred embodiments of the present invention, to those skilled in theart to which the present invention relates, the present disclosure willsuggest many modifications and constructions, as well as widelydiffering embodiments and applications without thereby departing fromthe spirit and scope of the invention.

What is claimed is:
 1. A method of making granular extrudate comprisingthe following steps: (a) providing an extruder having an extruder die, astarch-containing admixture for being extruded from the extruder bybeing discharged from the extruder die as granular extrudate, anextrudate discharge chamber in communication with the extruder die thatreceives the granular extrudate discharged from the extruder die, and anelongate discharge conduit in gas flow communication with the extrudatedischarge chamber for transporting the granular extrudate away from theextruder and the extrudate discharge chamber; (b) extruding thestarch-containing admixture from the extruder by gelatinizing thestarch-containing admixture and extruding the gelatinizedstarch-containing admixture by discharging the gelatinizedstarch-containing admixture from the extruder die into the extrudatedischarge chamber; and (c) transporting the granular extrudate from theextrudate discharge chamber into the discharge conduit by a gas flowingthrough (i) the extrudate discharge chamber and (ii) the dischargeconduit, the flowing gas quenching the granular extrudate duringtransport of the granular extrudate from the extrudate discharge chamberinto and through the discharge conduit without heating the granularextrudate during transport therethrough.
 2. The method of makinggranular extrudate of claim 1, wherein during quenching of the granularextrudate during the transport step (c), the granular extrudate iscooled and dried by the gas flowing through the extrudate dischargechamber and the discharge conduit.
 3. The method of making granularextrudate of claim 1, wherein during quenching of the granular extrudateduring the transport step (c), the granular extrudate is cooled anddried by the gas flowing through the extrudate discharge chamber and thedischarge conduit without heating of the granular extrudate.
 4. Themethod of making granular extrudate of claim 3, wherein after quenchingduring the transport step (c), the granular extrudate is comprised of atleast 10% cold water-soluble binder by weight formed of starch in theadmixture modified during extrusion of the granular extrudate.
 5. Themethod of making granular extrudate of claim 4, wherein the granularextrudate is comprised of extruded pellets.
 6. The method of makinggranular extrudate of claim 5, wherein quenching during the transportstep (c) dries and cools the extruded pellets substantially completelypreventing retrogradation of the cold water-soluble binder in theextruded pellets.
 7. The method of making granular extrudate of claim 5,wherein quenching during the transport step (c) dries and cools theextruded pellets substantially completely preventing crystallization orrecrystallization of the cold water-soluble binder in the extrudedpellets.
 8. The method of making granular extrudate of claim 5, whereinquenching during the transport step (c) dries and cools the extrudedpellets substantially completely preventing solubilization of the coldwater-soluble binder in the extruded pellets.
 9. The method of makinggranular extrudate of claim 1, wherein a temperature of the granularextrudate during quenching of the granular extrudate during thetransport step (c) is reduced at least 15 degrees Celsius from aninitial temperature of the granular extrudate during discharge of theextruded granular extrudate from the extruder die.
 10. The method ofmaking granular extrudate of claim 1, wherein during quenching duringthe transport step (c), the granular extrudate is dried during quenchingby reducing a moisture content of the granular extrudate duringdischarge of the granular extrudate from the extruder die to a moisturecontent of no greater than 13% by weight.
 11. The method of makinggranular extrudate of claim 1, wherein the granular extrudate iscomprised of extruded pellets that are: (a) cooled by quenching duringthe transport step (c) such that a temperature of the extruded pelletsafter quenching is at least 15 degrees Celsius less than a temperatureof the extruded pellets during discharge of the extruded pellets fromthe extruder; and (b) dried by quenching during the transport step (c)such that a moisture content of the extruded pellets after quenching isno greater than 13% by weight.
 12. The method of making granularextrudate of claim 11, wherein the during quenching during the transportstep (c), the temperature of the extruded pellets are reduced to atemperature of no greater than 83 degrees Celsius.
 13. The method ofmaking granular extrudate of claim 11, wherein the extruded pellets arecooled and dried without heating of the extruded pellets occurringduring quenching of the extruded pellets during the transport step (c).14. The method of making granular extrudate of claim 13, wherein afterquenching during the transport step (c), the extruded pellets arecomprised of at least 10% cold water-soluble binder by weight formed ofstarch in the admixture modified during extrusion of the extrudedpellets.
 15. The method of making granular extrudate of claim 1, whereinthe granular extrudate is comprised of extruded pellets extruded fromthe extruder, and wherein quenching of the extruded pellets during thetransport step (c) substantially completely prevents shrinkage of theextruded pellets.
 16. The method of making granular extrudate of claim15, further comprising a rotary cutter that cuts the granular extrudatedischarged from the extruder die into the extruded pellets, and whereineach extruded pellet shrinks during quenching during the transport step(c) less than 15% from an original size of the extruded pellet whendischarged from the extruder die and cut by rotary cutter.
 17. Themethod of making granular extrudate of claim 1, wherein the granularextrudate is comprised of extruded pellets extruded from the extruder,and wherein quenching of the extruded pellets during the transport step(c) substantially completely prevents densification of the extrudedpellets.
 18. The method of making granular extrudate of claim 17,further comprising a rotary cutter that cuts the granular extrudatedischarged from the extruder die into the extruded pellets, and whereineach extruded pellet increases in density during quenching during thetransport step (c) no more than 10% from an original density of theextruded pellet when discharged from the extruder die and cut by rotarycutter.
 19. The method of making granular extrudate of claim 1, whereinthe granular extrudate is comprised of extruded pellets extruded fromthe extruder, and wherein quenching of the extruded pellets during thetransport step (c) prevents the extruded pellets from shrinking morethan 15% and increasing in density more than 10% than a size and adensity of the extruded pellets as discharged from the extruder die. 20.The method of making granular extrudate of claim 19, wherein afterquenching during the transport step (c), the extruded pellets arecomprised of at least 10% cold water-soluble binder by weight formed ofstarch in the admixture modified during extrusion of the extrudedpellets.
 21. The method of making granular extrudate of claim 1, whereinduring quenching of the granular extrudate during the transport step(c), the gas flows turbulently through the extrudate discharge chamberand the discharge conduit.
 22. The method of making granular extrudateof claim 21, wherein the turbulently flowing gas is sucked through theextrudate chamber and the discharge conduit at a negative pressure thatis less than an ambient pressure.
 23. The method of making granularextrudate of claim 22, wherein the extrudate discharge chamber iscomprised of imperforate sidewalls, an imperforate top wall, and animperforate bottom wall.
 24. The method of making granular extrudate ofclaim 23, wherein during quenching of the granular extrudate during thetransport step (c), the granular extrudate is quenched by theturbulently flowing gas without heating of the granular extrudate. 25.The method of making granular extrudate of claim 23, wherein theturbulently flowing gas comprises turbulently flowing air, and whereinthe extrudate discharge chamber has one or more ports through whichambient air outside the extrudate discharge chamber can enter theextrudate discharge chamber.
 26. The method of making granular extrudateof claim 25, wherein the extruder has a rotary cutter that cuts thegranular extrudate into extruded pellets during discharge from theextruder, wherein the extrudate discharge chamber comprises a knife cageenclosing the extruder die and the rotary cutter, wherein the dischargeconduit comprises a pneumatic conveyor, and wherein the extruded pelletsare quenched by the turbulently flowing air while being transportedthrough the extrudate discharge chamber and the discharge conduit awayfrom the extruder during the transport step (c).
 27. The method ofmaking granular extrudate of claim 26, wherein during quenching of theextruded pellets during the transport step (c), the extruded pellets arecooled and dried by the turbulently flowing air without heating of theextruded pellets.
 28. The method of making granular extrudate of claim27, wherein after quenching during the transport step (c), the extrudedpellets are comprised of at least 10% cold water-soluble starches byweight formed of starch in the admixture modified during extrusion ofthe extruded pellets by the extruder.
 29. The method of making granularextrudate of claim 28, wherein quenching during the transport step (c)prevents retrogradation of the cold water-soluble starches in each oneof the extruded pellets.
 30. The method of making granular extrudate ofclaim 28, wherein quenching during the transport step (c) preventscrystallization or recrystallization of the cold water-soluble starchesin each one of the extruded pellets.
 31. The method of making granularextrudate of claim 28, wherein quenching during the transport step (c)prevents solubilization of the cold water-soluble starches in each oneof the extruded pellets.
 32. The method of making granular extrudate ofclaim 31, wherein after quenching during the transport step (c), theextruded pellets are comprised of at least 10% cold water-soluble binderby weight formed of starches in the admixture modified during extrusionof the extruded pellets by the extruder.